Patent Publication Number: US-2017367445-A1

Title: Fasteners bonded to substrate materials without puncturing the materials

Description:
RELATED APPLICATIONS 
     This application claims benefit of U.S. Provisional Application No. 62/355,706, filed Jun. 28, 2016, which is hereby incorporated by reference in its entirety. 
    
    
     TECHNICAL FIELD 
     This disclosure is directed to fasteners for use with clothing, bags and other accessories using a reusable molded closure design in the form of a post or other shape that can be directly injected, cast, bonded or molded onto a surface of the item to be fastened. 
     BACKGROUND 
     Traditionally, there are two different types of snaps used to join fabric or other loose materials: either a post-style or a prong-style. As shown in  FIG. 1 , the post-style has a shaft that extends through the fabric and the prong-style snap has barbs that penetrate through the fabric. Prong-style snaps attach onto the fabric with capped prong ring on one side and a socket or stud on the other side. Prong-style snaps are usually used on loosely woven or knit fabrics. Post-style snaps attach through the fabric with a capped post and corresponding stud or socket on the other side. Post-style snaps are usually used on densely woven and/or natural/synthetic fabrics. Snaps are available in brass, steel, stainless steel and plastics such as nylon and nylon blends. In both cases the snaps sandwich the material and due to penetration can weaken the fabric or material in that section. In addition, due to the sandwiching of the cap and socket or stud, you have added material stack-up height since there is a part on each side of the material. Thus, it becomes problematic if only one side of the material is available for mounting due to dimensional and/or comfort constraints. 
     Snaps are typically measured in ligne units which was used in France prior to adoption of the metric system (1 mm=0.4433 ligne). It is still used today to measure size of watch movements, buttons and ribbons. Thus, with snaps you are limited to ligne sizes and circular snaps. Due to sizing and shape constraints, typical snaps may not fully attach two materials or you may need to use multiple snaps which creates gaps between snaps or multiple snaps which creates more work for a user to attach. Snaps can also be ordered based on various force specs but this becomes more challenging as the snap becomes smaller in size and if a specific force is needed, custom tooling and larger production runs are required. 
     Another traditional fastener option used with loose fabrics and particularly clothing are buttons. However, buttons suffer from some of the same issues as snaps discussed above. They require a hole to be placed through one component of the material such that the button can be pushed through it. Buttons are sewn on, and the sewing often comes undone. Indeed, it is common to provide additional buttons with an item of clothing because this is such a common failure mode. Moreover, both buttons and snaps necessarily become a visible component of the object being fastened because they protrude through the surface. This may detract from the appearance of decorative fabrics. It would be beneficial to have a fastening system that does not protrude through the fabric material to be joined—both to protect the material integrity and to keep the fasteners out of sight. 
     Yet another prior art fastening system is velcro. Typically velcro is sewn onto a fabric, once again requiring perforation of the fabric. Alternatively, it is adhered with an adhesive, which may give way and leave a sticky residue. Moreover, velcro gets dirty over time and loses its strength, and also produces an audible sound when being pulled apart that has become associated with cheap or inexpensive designs. 
     Traditionally, snaps are rigid parts made of metal or injected-molded plastic. As disclosed below, the adjustable durometer closure (a) facilitates closures with a variety of durometers that provide a softer based closure that improves comfort, ease-of-use, and (b) facilitates seamless integration on a much wider array of fabrics onto which the closure can be directly injected, casted, bonded or molded. For example, instead of using capped post penetrating the material with a corresponding stud or socket, the adjustable durometer closure may be bonded on the material (such as on the inside surface where it is not visible during wear) with no penetration. 
     SUMMARY 
     The appended claims define this application. The present disclosure summarizes aspects of the embodiments and should not be used to limit the claims. Other implementations are contemplated in accordance with the techniques described herein, as will be apparent to one having ordinary skill in the art upon examination of the following drawings and detailed description, and these implementations are intended to be within the scope of this application 
     Example embodiments are disclosed for fasteners bonded to substrate materials without puncturing the materials. An example fastening system includes a male fastener component and a female fastener. The example male fastener component includes a base plate bonded to a first substrate material without puncturing the first substrate material, and a post integrally formed with the base plate, the base plate and the post formed of a polyurethane material. The example female fastener component includes a housing defining a cavity configured to engage with the post of the male fastener component. The housing is made of the polyurethane material and bonded to a second substrate material without puncturing the second substrate material. 
     An example fastening system a first fastener component and a second fastener component. The first fastener component is formed onto, via molding, to a first surface of a flexible material without puncturing the flexible material. Additionally, the first fastener component includes a plurality of posts. The second fastener component is formed onto, via molding, to a second surface of the flexible material without puncturing the flexible material. The second fastener component is configured to mate with the first fastener. 
     An method of fastening two surfaces includes inserting a post of a first fastening component into a cavity defined by a second fastening component. The first fastening component is molded onto a first surface without puncturing the first surface and the second fastening component molded onto a second surface without puncturing the second surface. The example method also includes applying force to the first fastening component and the second fastening component. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For a better understanding of the invention, reference may be made to embodiments shown in the following drawings. The components in the drawings are not necessarily to scale and related elements may be omitted, or in some instances proportions may have been exaggerated, so as to emphasize and clearly illustrate the novel features described herein. In addition, system components can be variously arranged, as known in the art. Further, in the drawings, like reference numerals designate corresponding parts throughout the several views. 
         FIG. 1  illustrates a post-style snap that has a shaft that requires a hole to penetrate a fabric and a prong-style snap that has barbs that penetrate through the fabric. 
         FIG. 2  illustrates exploded views of snap posts bonded to substrates in accordance with the teachings of this disclosure. 
         FIGS. 3A, 3B, and 3C  illustrate example straight snap posts. 
         FIGS. 4A, 4B, 4C, 4D, and 4E  illustrate example undercut snap posts. 
         FIG. 5  illustrates an example ledge post. 
         FIGS. 6A, 6B, 6C, 6D and 6E  illustrate an example set of posts that define an interlocking channel. 
         FIGS. 7A, 7B, and 7C  illustrate various closures based on the posts of  FIGS. 2, 3A, 3B, 3C, 4A, 4B, 4C, 4D, 4E, 5, and 6A, 6B . 
         FIGS. 8A and 8B  illustrate examples of male fastener component bonded to a substrate material. 
         FIGS. 9A and 9B  illustrate examples of female fastener component bonded to a substrate material. 
         FIG. 10  illustrates an example male fastener component snap fit with a corresponding female fastener. 
         FIG. 11  illustrates an example fastener component with posts arranged in an array bonded to a substrate material. 
         FIG. 12  illustrates a male fastener and a female fastener component bonded to a same substrate material. 
         FIG. 13  illustrates an example of a male fastener component bonded to a substrate material with a slot. 
         FIG. 14  illustrates a connector with both a male component and a female component connected together. 
         FIG. 15  illustrates a male fastener component and a female fastener component bonded to a substrate material that, when engaged, form a gasket. 
         FIG. 16  is an example of a fastener bonded with an article. 
     
    
    
     DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS 
     As describe below, a mating pair of posts and/or slots (sometimes referred to as “fastener components”) are bonded directly to a first surface of a flexible or semi-rigid material (sometime referred to herein as “fabric” or a “substrate material”) using a molding technique such as compression molding. While the term “fabric” is used, one of ordinary skill in the art will recognize that the invention disclosed herein could be used to join various materials together across numerous applications. For example, the present invention provides a stronger, more versatile, and more attractive alternative to a velcro bond, and could be used across essentially the same broad functions for which velcro is used (e.g., not just clothing, but numerous applications where two surfaces are to be temporarily joined.) 
     To form the bond between the fastener components and the fabric, a polyurethane blend is spread on a tool and closed in a vacuum to eliminate air bubbles. The polyurethane blend is placed in an oven to be allowed to cure slightly. The fabric is placed over the tools and placed in a heat press under pressure to finalize curing and bonding the fastener components to the fabric. In such a manner, the posts and/or slots are affixed to the fabric without puncturing the fabric. In some examples, the posts and/or slots are bonded directly onto the fabric. Alternatively, in some examples, the post and/or slots are integrally formed with a base plate of the same material that is bonded directly onto the fabric without puncturing the fabric. In some such examples, the base plate is thin (e.g., less than a millimeter) and flexible to flex with the fabric. In some examples, the base plate of the posts is flexible and the base plate of the slots is rigid. The posts are configured to mate with the corresponding slots. In some examples, the posts and slots are configured to press fit together. To press fit together, the posts are forced under pressure into a slightly smaller diameter slot and held together by friction. In some examples, the posts and slots are configured to snap fit together. To snap fit together, the posts include a flared lip and the slots are resilient and flexibly extend to receive and contract around the flared lip. In some examples, an array of posts is configured to mate with a corresponding array of posts via an interlocking fit. Additionally, the posts may be configured to mate with a non-flexible slot within an item. For example, the post may be configured to mate with a universal serial bus (USB) port on a cellular phone or speaker to aid retention thereto. 
       FIG. 2  illustrates exploded views of posts  200  bonded to substrates  202  and  204  in accordance with the teachings of this disclosure. The posts  200  are formed by applying polyurethane (PU) to a casting mold (not shown). The substrate(s)  202  and  204  are positioned on the casting mold and pressure is applied to the substrate(s)  202  and  204 , the polyurethane, and the casting mold. The pressure cures the polyurethane in the shape of the casting mold (e.g., the posts  200 ) and adheres the polyurethane posts  200  to the substrate(s)  202  and  204 . In some examples, the bonding strength of the posts  200  and the substrate material  202  and  204  is at least 2.5 kilograms per centimeter squared. In some examples, the durometer of the cured posts  200  is 45 Shore A to 90 Shore A hardness. In the illustrated example, the substrates include a flexible or semi-rigid substrate material  202  and/or a hot melt film  204 . In some examples, the posts  200  are bonded to a substrate material or a combination of substrate materials. For examples, the posts  200  may be bonded to (a) the flexible or semi-rigid substrate material  202 , (b) the hot melt material  204 , or (c) a combination of the flexible or semi-rigid substrate material  202  and the hot melt material  204 . As another example, the posts  200  may be bonded to the flexible or semi-rigid substrate material  202  while the flexible or semi-rigid substrate material  202  is bonded to the hot melt material  204 . The flexible or semi-rigid substrate material  202  may include any suitable flexible or semi-rigid material, singly or in combination, such as neoprene, leather, cotton, wool, nylon, polyester, polypropylene, rayon, and/or lycra, etc. Additionally, the substrates may be solid, knit, or woven, etc. 
       FIGS. 3A, 3B, and 3C  illustrate example straight posts  300 . The straight posts  300  of  FIGS. 3A, 3B, and 3C  are examples of posts that mate with a corresponding slot through press fitting. The straight posts  300  are an example of the posts  200  of  FIG. 2 .  FIG. 2A  is a perspective view of an example straight posts  300 . In the illustrated example of  3 A, the straight posts  300  includes a cap  302 , a body  304 , and a flange  306 . The cap  302  includes a tapered portion so that a base of the cap  302  has different dimensions than a top of the cap  302 . The base of the cap  302  and the top of the body  304  of the straight posts  300  have the same cross-section and are the same dimensions. In the illustrated example, the height of the body  304  is greater than the height of the cap  302 . However, the ratio of the height of the body  304  and the height of the cap  302  may vary. The flange  306  flares out from a base of the body  304  to increase the bonding area between the straight posts  300  and the substrate(s)  202  and  204  of  FIG. 2  to provide adhesion and strength.  FIG. 3B  illustrates top views and sides views of the straight posts  300  that do not include the flange  306  of  FIG. 3A . In the illustrated examples of  FIGS. 3A and 3B , the cap  302  and the body  304  of the straight posts  300  have a circular, a superellipse (sometimes referred to as a “squircle”), and a hexagonal horizontal cross-section. However, the cap  302  and the body  304  of the straight posts  300  may have any elliptical, regular polygon, or irregular polygon cross-section. Indeed, the present invention is not limited geometrically like traditional snaps, and can instead take on decorative outlines/shapes while still providing the desired temporary fastening function. 
     Additionally, in some examples, the cross-section of the cap  302  and the body  304  is different from the cross-section of the flange  306 . For example, the cap  302  and the body  206  may have a hexagonal cross-section and the flange  306  may have a circular cross-section.  FIG. 3C  illustrated a side view of the straight posts  300 . As illustrated in  FIG. 3C , in some examples, the straight post  300  is made of different types of polyurethane that have different durometers. In the illustrated example of  FIG. 3C , the cap  302  is made of a first polyurethane layer  308  that has a first durometer and the body  304  are made of a second polyurethane layer  310  that has a second, different durometer. For example, the first polyurethane layer  308  may have a shore durometer of 55 and the second polyurethane layer  310  may have a shore durometer of 70. 
       FIGS. 4A, 4B, 4C, 4D, and 4E  illustrate example undercut posts  400  with flared lips. The undercut posts  400  are an example of the posts  200  of  FIG. 2 . The undercut posts  400  of  FIGS. 4A, 4B, 4C, 4D, and 4E  are examples of posts that mate with corresponding slots through snap fitting. In the illustrated example of  FIG. 4A , the undercut post  400  include a cap  402  and a body  404 . In some examples, the undercut post  400  also includes a flange  406 . In the illustrated example, the base of the cap  402  has a larger diameter than the top of the body  404 . In the illustrated example of  FIG. 4B , the cross-sections of the cap  402  and the body  404  of the undercut post  400  are rectangles.  FIG. 4C  illustrates the undercut post  400  that includes the cap  402  with a straight bevel  408 . The difference between the base of the cap  402  and the top of the body  404  defines an overhang  410  that has a length L. Additionally, the body  404  has a height H.  FIG. 4D  illustrates the undercut post  400  that includes the cap  402  with a curved bevel  412 . The difference between the base of the cap  402  and the top of the body  404  defines an overhang  410  that has a length L. Additionally, the body  404  has a height H.  FIG. 3D  illustrates the undercut post  400  that includes the cap  402  with a tapered base  414 . The bottom of the tapered base  414  matches the top of the body  404 . The difference between the top of the tapered base  414  (e.g., the widest portion of the cap  402 ) and the top of the body  404  defines a length L. Additionally, the tapered base  414  tapers at an angle θ. 
       FIG. 5  illustrates an example ledge post  500 . The ledge post  500  is an example of the posts  200  of  FIG. 2 . In the illustrated example, the ledge post  500  includes a cap  502  and a body  504 . In the illustrated example, the cross-section of the cap  502  is larger than the cross-section of the body  504 . Additionally, the body  504  is offset to one of the sides of the cap  502 . The ledge post  500  is configured so that when a first ledge post  506  is bonded to a first substrate  508 , and a second ledge post  510  is bonded to a second substrate  512 , the first ledge post  506  interlocks with the second ledge post  510 . 
       FIGS. 6A, 6B, 6C, 6D, and 6E  illustrate an example set of posts  600  and  602  that define an interlocking channel  604 . The posts  600  and  602  are an example of the posts  200  of  FIG. 2 .  FIG. 6A  illustrates a top view of a first fastener component comprising a first set of posts  600  bonded to a first substrate  606  to define the interlocking channel  604 .  FIG. 6B  illustrates a cross-section of the posts  600  bonded of the first substrate  606 . The posts  600  have a tapered wall  608 .  FIG. 6C  illustrates second fastener component comprising a second post  602  bonded to a second substrate  610 . The second post  602  is configured to interlock with the first posts  600  when the first and second fastener components are connected.  FIG. 6D  illustrates a cross-section of the second post  602 . The second post comprises tapered walls  612  configured to interlock with tapered walls  608  of the first set of posts  600  so that (a) when a vertical force is applied to the fastener components, the fastener components remain interlocked, and (b) when a horizontal force is applied to the fastener components, the fastener components, the second post  602  slides in the interlocking channel  604  defined by the first posts  600 .  FIG. 6E  illustrates a cross-section of the first substrate  606  connected to the second substrate  610  via the first and second fastener components. In the illustrated example, the second post  602  fits within the interlocking channel  604  defined by the first set of posts  600 . 
       FIGS. 7A, 7B, and 7C  illustrate various closures  700 - 704  based on the posts  200 ,  300 ,  400 ,  500 ,  600 , and  502  of  FIGS. 2, 3A, 3B, 3C, 4A, 4B, 4C, 4D, 4E, 5 , and  6 A,  6 B.  FIG. 7A  illustrates a closure  700  that defines a cutout portion  708 . In the illustrated example, the cutout portion  708  is sized so that a body of an undercut post (e.g., the undercut post  400  of  FIGS. 4A, 4B, 4C, 4D, and 4E ) is movable within the cutout portion  708  and the cap of the undercut post prevents the undercut post  400  from being removed from the closure  700  without the application of force.  FIG. 7B  illustrates a closure  702  defining multiple slots  710  to accept posts  200  bonded to a substrate  712 . For example the closure  702  and the substrate  712  may be watch bands or straps of a baseball cap. This embodiment conveniently allows for clothing items (for example) to be adjusted without tailoring or alterations. 
       FIG. 7C  illustrates a post  704  with a non-geometric shape bonded to a first substrate (not shown) interlocking with the posts  200  acting as a closure bonded to a second substrate  714 . A non-geometric shape is a decorative or ornamental shape that does not have a defined geometric pattern (e.g., geometric patterns such as a triangle, a rectangle, a square, a circle, a pentagon, a hexagon, a oval, a parallelogram, a trapezoid, a rhombus, etc.). In the illustrated example, the post  704  has an organic shape to snap fit into a path defined by the posts  200 . 
       FIGS. 8A and 8B  illustrate examples of male fastener component  800  and  802  bonded to the substrate material  202  and  204 .  FIG. 8A  illustrates the male fastener component  800  that includes posts  804  integrally formed with a base plate  806 . In the illustrated example, the post  804  includes a flared lip for snap fitting with a corresponding female fastener. However, the posts may be any of the example posts  200 ,  300 ,  400 ,  500 ,  600 , and  502  of  FIGS. 2, 3A, 3B, 3C, 4A, 4B, 4C, 4D, 4E, 5, and 6A, 6B . The base plate  806  is bonded (e.g., via compression molding) to the substrate material  202  and  204 . The base plate  806  may be of any desired thickness. In some examples, the base plate  806  is flexible to deform with the substrate material  202  and  204 . In some examples, the base plate  806  is less than one millimeter (mm) thick.  FIG. 8B  illustrates the male fastener component  802  without the base plate  806  of  FIG. 8A . The posts  804  of the male fastener component  802  are bonded to the substrate material  202  and  204  without being otherwise connected to each other. In this arrangement, even though the posts  804  are not connected other than via the substrate material, the posts  804  together comprise the male fastener component  802 . 
       FIGS. 9A and 9B  illustrate examples of female fastener component  900  and  902  bonded to a substrate material  202  and  204 .  FIG. 9A  illustrates the female fastener component  900  defining cavities  904  configured to accept posts (e.g, the posts  200 ,  300 ,  400 ,  500 ,  600 , and  502  of  FIGS. 2, 3A, 3B, 3C, 4A, 4B, 4C, 4D, 4E, 5, and 6A, 6B ) to form a snap fit or a press fit. In the illustrated example, the cavities  904  are configured to accept a post with a flared lip to form a snap fit.  FIG. 9B  illustrates the female fastener component  902 . The female fastener component  902  comprises housings  906  which define the cavities  904  that are configured to accept posts. Although, the housings  906  are not connected other than via the substrate material, the based  906  together comprise the female fastener component  902 . 
       FIG. 10  illustrates the example male fastener component  800  snap fit with the corresponding female fastener component  900 . The posts  804  of the male fastener component  800  engage with the cavities  904  of the female fastener component  900 . In the illustrated example, the posts  804  have a flared lip and the corresponding cavities are configured to engage with the flared lip to snap fit the male fastener component  800  and the female fastener component  900 . However, the posts  804  and the cavities  904  may be configured to engage to form a press fit. 
       FIG. 11  illustrates an example array fastener  1100  with posts  1102  arranged in an array bonded (e.g., via compression molding) to the substrate material  202  and  204 . The posts  1102  are spaced to engage another array fastener  110  to form an interlocking fit, where flared lips of the posts  1102  of one of the array fastener  1100  interlock with the flared lips of the posts  1102  of one of the other array fastener  1100 . 
       FIG. 12  illustrates a male fastener component  1200  and a female fastener component  1202  bonded to the same substrate material  202  and  204 . The fastener components  1200  and  1202 , when engaged, cause the substrate material  202  and  204  to form a loop. In some examples, the male fastener component  1200  includes multiple posts to facilitate adjusting the size of the loop.  FIG. 13  illustrates an example of a male fastener component  1300  bonded to the substrate material  202  and  204  defining a slot  1302  on an end opposite the male fastener component  1300 . When the slot  1302  engages with the posts of the male fastener component  1300 , the the substrate material  202  and  204  to forms a loop, In the illustrated example, the the male fastener component  1300  includes multiple posts to facilitate adjusting the size of the loop. 
       FIG. 14  illustrates a connector  1400  with both a male fastener component  1402  integrally formed with a female fastener component  1404 . The male fastener component  1402  is on a first end  1406  and the female fastener component  1404  is on the second end  1408 . A post  1410  of the male fastener component  1402  is configured to engage with a cavity  1412  defined by the female fastener component  1404 . In the illustrated example, the post  1410  of the male fastener component  1402  has a flared lip configured to snap fit into the cavity  1412 . To snap fit, the resilient female fastener component  1404  flexibly extends to receive and contract around the flared lip. 
       FIG. 15  illustrates a male fastener component  1500  and a female fastener component  1502  bonded to the substrate material  202  and  204  that, when engaged, form a gasket. The gasket fills the space between two surfaces to hinder leakage (e.g., fluid, electromagnetic radiation, etc.) into and/or out of the interior space that the gasket surrounds. The male fastener component  1500  includes a continuous post  1504  that extend from the surface of the male fastener component  1500  around the geometry of the male fastener component  1500 . The female fastener component  1502  defines a continuous cavity  1506  configured to engage with the continuous post  1504 . In the illustrated example, the continuous post  1504  of the male fastener component  1500  includes a flared lip to snap fit with the continuous cavity  1506  of the female fastener component  1502 . In some examples, bodies  1508  of the fastener components  1500  and  1502  are formed of a material with a relatively hard durometer and the continuous post  1504  of the male fastener component  1500  is formed of a material with a softer durometer. In some such examples, the continuous post  1504  of the male fastener component  1500  is resilient and the flared lip flexibly engages into the continuous cavity  1506  of the female fastener component  1502 . 
       FIG. 16  is an example of fastener components  1600  bonded with an article  1602 . In the illustrated example, the fastener components  1600  are male fastener components. However, the fastener components  1600  may be female fastener components or a combination of male and female fastener components. The fastener components  1600  are bonded to a surface of the article  1602 . As a result, the substrate material  202  and  204  is not punctured. Because the substrate material  202  and  204  is not punctured, the article  1602  may be waterproof or water resistant. 
     As can be seen from these examples, various geometries are made possible by the new method of attaching posts to textiles that does not require the textile to be pierced. Additionally, this method does not require the textile to be reinforced or backed. Additionally, the posts of the illustrated examples facilitate an interface between soft goods (e.g., a helmet liner) and hard goods (e.g., a helmet). In some examples, the textile may be worn next to the skin without ameliorating the contact on the skin of the back of the post-style snap and the prong-style snap.