Patent Abstract:
The invention relates to molding systems and related methods. In one aspect of the invention, a molding apparatus includes a first cylindrical roll that is rotatably coupled to a frame arid an adjacent pressure device, the frame is configured so that a substrate can pass through a nip formed between the first cylindrical roll and the pressure device while a portion of the substrate extends laterally beyond at least the frame and the first cylindrical roll.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation of U.S. Ser. No. 11/748,427, filed May 14, 2007; which is a continuation-in-part of U.S. Ser. No. 11/082,384, filed Mar. 17, 2005 and also a continuation-in-part of U.S. Ser. No. 11/005,185, filed Dec. 6, 2004, now U.S. Pat. No. 7,285,407; which is a divisional of Ser. No. 10/163,169 filed Jun. 4, 2002, now U.S. Pat. No. 6,991,843; which is a continuation-in-part of U.S. Ser. No. 09/808,395, filed Mar. 14, 2001, now U.S. Pat. No. 7,048,818. The entire contents of each of the foregoing are hereby incorporated by reference. 
     
    
     TECHNICAL FIELD 
       [0002]    This invention relates to molding apparatus and related methods. 
       BACKGROUND 
       [0003]    Early male-touch fastener products were generally woven materials, with hooks formed by cutting filament loops. More recently, arrays of small fastener elements have been formed by molding the fastener elements, or at least the stems of the elements, of resin, forming an interconnected sheet of material. Generally, molded plastic hook tape has displaced traditional woven fabric fasteners for many applications, primarily because of lower production costs. 
         [0004]    Molded plastic hook tape is often attached to substrates by employing an adhesive, or by sewing when the substrate is a made from sewable material. Often, adhesive-backed hook tape is utilized to attach the hook tape at desired locations on the substrate. Unfortunately, me process of applying adhesive-backed hook tape can be slow, and adhesion of the adhesive-backed hook tape to the substrate can be poor. 
       SUMMARY 
       [0005]    Generally, the invention relates to molding apparatus and related methods. 
         [0006]    In one aspect, the invention features a method of molding projections on a substrate. The method includes introducing a substrate having an outer surface into a gap formed between a peripheral surface of a rotating mold roll that defines a plurality of discrete cavities that extend inwardly from the peripheral surface, and a supporting surface. Resin is delivered to a nip formed between the outer surface of the substrate and the peripheral surface of the rotating mold roll. The outer surface of the substrate and the peripheral surface of the rotating mold roll are arranged to generate sufficient pressure to at least partially fill the cavities in the mold roll as the substrate is moved through the gap to mold an array of discrete projections including stems that extend integrally from a layer of the resin bonded to the substrate. The molded projections are then withdrawn from their respective cavities by separation of the peripheral surface of the mold roll from the outer surface of the substrate by continued rotation of the mold roll. The substrate o has a beam stiffness, measured as a product of an overall moment of inertia of a nominal transverse cross-section and an effective modulus of elasticity of a material from which the substrate is formed, that is greater than about 200 lb-in 2  (0.574 N-m 2 ). 
         [0007]    In some embodiments, the beam stiffness is greater than 1,000 lb-in 2  (2.87 N-m 2 ), e.g., 4,000 lb-in 2  (11.48 N-m 2 ) or more, e.g., 8,000 lb-in 2  (22.96 N-m 2 ). 
         [0008]    In some instances, the effective modulus of elasticity of the material from which the substrate is formed is greater than 100,000 psi (6.89×10 8  N/m 2 ), e.g., 250,000 psi (1.72×10 9  N/m 2 ), 750,000 psi (5.17×10 9  N/m 2 ), 1,000,000 psi (6.89×10 9  N/m 2 ) or more, e.g., 5,000,000 psi (3.45×10 10  N/m 2 ), 15,000,000 psi (1.03×10 11  N/m 2 ) or more, e.g., 30,000,000 psi (2.07×10 11  N/m 2 ). 
         [0009]    In some implementations, the supporting surface is a peripheral surface of a counter-rotating pressure roll or a fixed pressure platen. 
         [0010]    In some embodiments, the cavities of the mold roll are shaped to mold hooks so as to be engageable with loops. In other embodiments, the cavities of the mold roll are shaped to mold hooks, and the hooks are reformed after molding. 
         [0011]    In some instances, each projection defines a tip portion, and the method further includes deforming the tip portion of a plurality of projections to form engaging heads shaped to be engageable with loops, or other projections, e.g., of a complementary substrate. 
         [0012]    In some embodiments, the resin is delivered directly to the nip. In some implementations, the resin is delivered first to the outer surface of the substrate upstream of the nip, and then the resin is transferred to the nip, e.g., by rotation of the mold roll. 
         [0013]    The substrates can have a variety of shapes, e.g., the substrate can have an “L” shape, “T” shape or “U” shape in transverse cross-section. 
         [0014]    In some embodiments, the method further includes introducing another resin beneath the resin such that the other resin becomes bonded to the outer surface of the substrate and the resin becomes bonded to an outer surface of the other resin. 
         [0015]    The substrate can have, e.g., an average surface roughness of greater than 1 micron, e.g., 2 micron, 4 micron, 8 micron, 12 micron or more, e.g., 25 micron. 
         [0016]    In some implementations, the substrate is formed from more than a single material. 
         [0017]    In some instances, the projections have a density of greater than 300 projections/in 2  (46.5 projections/cm 2 ). 
         [0018]    In some embodiments, the method further comprises pre-heating the substrate prior to introducing the substrate into the gap, or priming the substrate prior to introducing the substrate into the gap. 
         [0019]    In another aspect, the invention features a method of molding projections on a substrate. The method includes introducing a substrate, e.g., a linear substrate, having an outer surface into a gap formed between a peripheral surface of a rotating mold roll that defines a plurality of discrete cavities that extend inwardly from the peripheral surface, and a supporting surface. The resin is delivered to a nip formed between the outer surface of the substrate and the peripheral surface of the rotating mold roll. The outer surface of the substrate and the peripheral surface of the rotating mold roll are arranged to generate sufficient pressure to at least partially fill the cavities in the mold roll as the substrate is moved through the gap to mold an array of discrete projections including stems extending integrally from a layer of the resin bonded to the substrate. The molded projections are withdrawn from their respective cavities by separation of the peripheral surface of the mold roll from the outer surface of the substrate by continued rotation of the mold roll. The substrate has a beam stiffness sufficiently great that during withdrawal of the molded projections from their respective cavities, the substrate remains substantially linear. 
         [0020]    In some embodiments, the beam stiffness of the substrate, measured as a product of an overall moment of inertia of a nominal transverse cross-section and an effective modulus of elasticity of material of the substrate, is greater than about 200 lb-in 2  (0.574 N-m 2 ). 
         [0021]    In another aspect, the invention features an article having molded fastening projections. The article includes a substrate and an array Of discrete molded projections including stems extending outwardly from and integrally with a molded layer of resin solidified about surface features of the substrate, and thereby securing the projections directly to the substrate. The substrate has a beam stiffness, measured as a product of an overall moment of inertia of a nominal transverse cross-section and an effective modulus of elasticity of a material from which the substrate is made, that is greater than about 200 lb-in 2  (0.574 N-m 2 ). 
         [0022]    In some embodiments,, the beam stiffness is greater than about 1,000 lb-in 2  (2.87 N-m 2 ), e.g., 4,000 lb-in 2  (11.48 N-m 2 ). 
         [0023]    Embodiments may have one or more of the following advantages. Projections can be integrally molded onto substrates, e.g., substrates useful in construction, e.g., wallboard, window frames, panels, of tiles, without the heed for using an adhesive, often reducing manufacturing costs, e.g., by reducing labor costs and increasing throughput. Integrally molding projections often improves adhesion of the molded projections to the substrate and reduces the likelihood of delamination of the molded projections from the substrate during the application of a force, e.g., a peeling force, or a shear force. 
         [0024]    In situ lamination of hook, bands or islands on rigid materials held in a planar orientation or presenting a planar surface, extend in rigid flexible materials is also featured. 
         [0025]    All publications, patent applications, patents, and other references mentioned herein are incorporated by reference herein in their entirety. 
         [0026]    Other features and advantages of the invention will be apparent from the following detailed description, and from the claims. 
     
    
     
       DESCRIPTION OF DRAWINGS 
         [0027]      FIG. 1  is a side view of a process for molding hooks onto a T-shaped substrate, the process utilizing a fixed pressure platen as a supporting surface for the T-shaped substrate. 
           [0028]      FIG. 1A  is a cross-sectional view taken along  1 A- 1 A of  FIG. 1 . 
           [0029]      FIG. 1B  is an enlarged side view of Area  1 B of  FIG. 1 . 
           [0030]      FIG. 1C  is a cross-sectional view taken along  1 C- 1 C of  FIG. 1 . 
           [0031]      FIG. 2  is a side view of an alternative process for molding hooks onto a substrate, the process utilizing a counter-rotating pressure roll as support for the substrate. 
           [0032]      FIG. 2A  is an enlarged, side view of a reforming roll (Area  2 A) of  FIG. 2 . 
           [0033]      FIG. 3  is a side view of a process for molding stems onto a substrate. 
           [0034]      FIG. 3A  is an enlarged side view of Area  3 A of  FIG. 3 , showing a substrate having molded stems. 
           [0035]      FIG. 4  is a side view of a process for reforming the molded stems of  FIG. 3  to form engageable projections shaped to be engageable with loops ( FIG. 4B ) or other projections. 
           [0036]      FIG. 4A  is an enlarged side view of Area  4 A of  FIG. 4 . 
           [0037]      FIG. 4B  is an enlarged cross-sectional view of a substrate carrying fibrous loops. 
           [0038]      FIG. 4C  is a side view of two substrates having deformed molded stems, illustrating how the two substrates can engage each other. 
           [0039]      FIG. 5  is a side view of a process for molding hooks onto a substrate that utilizes a tie layer. 
           [0040]      FIG. 5A  is an enlarged side view of Area  5 A of  FIG. 5 . 
           [0041]      FIGS. 6 and 7  are cross-sectional views of planar, laminated substrates, having two and three layers, respectively; 
           [0042]      FIG. 8A  is a cross-sectional view of an L-shaped substrate having hooks in which heads are directed in a single direction, and  FIG. 8B  is a perspective view of the L-shaped substrate of  FIG. 8A . 
           [0043]      FIG. 9  is cross-sectional view a U-shaped substrate haying molded projections. 
           [0044]      FIG. 10  is a front view of a fastener element molding apparatus of the present invention applying fastener elements to a planar sheet or work piece. 
           [0045]      FIG. 11  is an isometric view of the apparatus of  FIG. 10  illustrating only the fastener element mold roil portion of the apparatus applying engageable fastener elements to a sheet or work piece. 
           [0046]      FIG. 12  is a cross-sectional view of the mold roll of  FIG. 11  taken along line  12 - 12  of  FIG. 11 . 
       
    
    
       [0047]    Like reference symbols in the various drawings indicate like elements. 
       DETAILED DESCRIPTION  
       [0048]    Rigid or elastically stretchable substrates having molded fastener projections, and methods of making the same are described herein. Generally, rigid substrates have a beam stiffness that is sufficiently great such that during withdrawal of the molded projections from their respective cavities, the substrate remains substantially straight, and does not bend away from its support. In other cases, elastically stretchable substrates have flexibility in only one orthogonal direction. The elastic material is arranged with the stretchable direction lying in the cross machine direction. 
         [0049]    Referring collectively to FIGS.  1  and  1 A- 1 C, a process  10  for integrally molding projections, e.g., hooks  12 , onto a substrate  14 , e.g., a T-shaped substrate, includes introducing the substrate  14  that has an outer surface  16  into a gap  18  formed between a peripheral surface  20  of a rotating mold roll  22  and a fixed pressure platen  24  that has a supporting surface  27 . The mold roll  22  defines a plurality of discrete cavities, e.g., cavities  26  in the shape of hooks, that extend inwardly from peripheral surface  20  of the rotating mold roll  22 . An extruder (not shown) pumps resin  30 , e.g., molten thermoplastic resin, through a die  31  where it is delivered to a nip N formed between outer surface  16  of the substrate and peripheral surface  20  of the rotating mold roll  22 . The outer surface  16  of the substrate  14  and peripheral surface  20  of rotating mold roll  22  are arranged to generate sufficient pressure to fill the cavities in the mold roll  22  as substrate  14  is moved through gap  18  to integrally mold an array of discrete hooks  12 , including stems  34 , which extend outwardly from and are integral with a layer  40  that is bonded to outer surface  16 . The molded hooks  12  are withdrawn from their respective cavities  26  by separation of the peripheral surface  20  of the mold roll  22  from outer surface  16  of substrate  14  by continued rotation of mold roll  22 . Substrate  14  has a beam stiffness sufficiently great such that during withdrawal of hooks  12  from their respective cavities, the substrate  14  remains substantially linear, and is not bent away from the supporting surface  27  of fixed pressure platen  24  toward moll roll  22  (indicated by arrow  29 ). For example, substrate  14  has a beam stiffness, measured as a product of an overall moment of inertia of a nominal transverse cross-section and an effective modulus of elasticity (Young&#39;s modulus) of a material from which the substrate is formed, that is, e.g., greater than 1,000 lb-in 2  (2.87 N-m 2 ), e.g., 4,000 lb-in 2  (11.48 N-m 2 ) or greater, e.g., 8,000 lb-in 2  (22.96 N-m 2 ). The effective modulus of elasticity of the material from which the substrate is formed is measured using ASTM E111-04 at 25° C. at fifty percent relative humidity, allowing sufficient time for moisture and temperature equilibration. 
         [0050]    In some implementations, the outer surface  16  of substrate  14 , the peripheral surface  20  of the rotating mold roll  22  and the resin  30  are arranged to generate sufficient friction such that the substrate  14  is pulled into and moved through gap  18 , in a direction indicated by arrow  41 , by continued rotation of mold roll  22 . 
         [0051]    In some embodiments, mold roll  22  includes a face-to-face assembly of thin, circular plates or rings (not shown) that are, e.g., about 0.003 inch to about 0.250 inch (0.0762 mm-6.35 mm) thick, some rings having cutouts in their periphery that define mold cavities, and other rings having solid circumferences, serving to close the open sides of the mold cavities and to serve as spacers, defining the spacing between adjacent projections. In some embodiments, adjacent rings are configured to mold hooks  12  such that alternate rows  50 ,  52  ( FIG. 1B ) have oppositely directed heads. A fully “built up” mold roll may have a width, e.g., from about 0.75 inch to about 24 inches (1.91 cm-61.0 cm) or more and may contain, e.g., from about 50 to 5000 or more individual rings. Further details regarding mold tooling are described by Fisher, U.S. Pat. No. 4,775,310, the disclosure of which is hereby incorporated by reference herein in its entirety. 
         [0052]    Referring to  FIG. 2 , in an alternative embodiment, the supporting surface for substrate  14  is a peripheral surface  54  of a counter-rotating pressure roll  56 . As discussed above, an extruder (not shown) pumps resin through die  31  and delivers the resin  30  to nip N to mold an array of discrete hooks  12  extending integrally from layer  40  that is bonded to the substrate. While an extruder (not shown) can pump resin  30  directly into the nip N, other points of delivery are possible. For example, as shown in  FIG. 2 , rather than delivering resin directly to nip N, extruder die  31  can be positioned to deliver resin  30  first to the outer surface  16  of substrate  14  upstream of the nip N. In this embodiment, resin  30  is transferred to nip N by moving substrate  14  through gap  18 . This can be advantageous, e.g., when it is desirable that the resin  30  be somewhat set, e.g., cooled, prior to entering the nip N. In other embodiments, also as shown in  FIG. 2 , extruder die  31  is positioned to deliver resin  30  first to the outer surface  20  of the rotating mold roll  22 . In this implementation, resin  30  is transferred to the nip N by rotation of the mold roll  22 . 
         [0053]    Referring particularly to  FIG. 2A , in some instances, hooks  71  remain slightly 
         [0054]    deformed after being withdrawn from their respective cavities during separation of the peripheral surface  20  from the outer surface  16  of substrate  14 . To return these hooks to their as-molded shape, the process shown in  FIG. 2  can optionally include a reforming roll  70  that reforms deformed hooks  71  with pressure and, optionally, heat as the molded hooks move below the reforming roll  70 . In some instances, it is desirable that the reforming roll  70  be rotated such that it has a tangential velocity that is higher than, e.g., ten percent higher or more, e.g., twenty-five percent higher, than the velocity of the. substrate  14  to aid in the reforming of the deformed hooks. In some instances, reforming roll  70  can be used to maintain substrate  14  in a substantially linear state, by hindering movement of substrate  14  toward the mold roll. 
         [0055]    In some embodiments, the process shown in  FIG. 2  can optionally include a counter rotating nip-roller  74  in conjunction with the reforming roll  70  to aid in the moving of substrate  14  through gap  18 . 
         [0056]    Referring now to  FIGS. 3 and 3A , in an alternative embodiment, a process  90  for integrally molding projections in the shape of stems  82  onto substrates includes a mold roll  22  that defines a plurality of discrete cavities  80  in the shape of stems  82  that extend inwardly from a peripheral surface  20  of the rotating mold roil  22 . In some instances, removal of molded projections that are in the shape of stems  82  from a mold roll can be easier (relative to projections in the shape of hooks) because the mold roll does not have cavities that have substantial undercuts. As a result, substrate  14  can often have a lower beam stiffness (relative to embodiments of  FIGS. 1 and 2 ) and still remain substantially linear during withdrawal of the stems  82  from their respective cavities  80 . For example, the substrate can have a beam stiffness that is, e.g., greater than 200 lb-in 2  (0.574 N-m 2 ), e.g., 1,000 lb-in 2  (2.87 N-m 2 ). 
         [0057]    Referring to  FIGS. 4-4C , the projections in the shape of stems  82  that were integrally molded to substrate  14  by the process shown in  FIG. 3  can be deformed (such as when a thermoformable resin is employed to mold the stems) by a deforming process  100 . Process  100  can form engaging heads  102  shaped to be engageable with loops  103  that extend from a base  104  of a mating material ( FIG. 4B ), or that are engageable with other projections  102 ′ of a mating substrate  106  ( FIG. 4C ). 
         [0058]    Referring particularly to  FIG. 4 , a heating device  110  includes a heat source  111 , e.g., a non-contact heat source, e.g., a flame, an electrically heated wire, or radiant heat blocks, that is capable of quickly elevating the temperature of material that is close to heat source  111 , without significantly raising the temperature of material that is further away from heat source  111 . After heating the stems  82 , the substrate moves to conformation station  112 , passing between conformation roll  114  and drive roll  116 . Conformation roll  114  deforms stems  82  to form engageable heads  102 , while drive roll  116  helps to advance the substrate. 
         [0059]    It is often desirable to chill the conformation roll, e.g., by running cold water through a channel  115  in the center of roll  114 , to counteract heating of conformation roll  114  by the heat of the resin. Process  100  can be performed in line with the process shown in  FIG. 3 , or it can be performed as a separate process. Further details regarding this deforming process are described by Clarner, U.S. patent application Ser. No. 10/890,010, filed Jul. 13, 2004, the entire contents of which are incorporated by reference herein. 
         [0060]    Referring now to  FIGS. 5 and 5A , in an alternative embodiment, an extruder (not shown) pumps resin  30  through die  31 , and delivers resin  30  to nip N formed between outer surface  16  of substrate  14  and peripheral surface  20  of rotating mold roll  22 . At the same time, a second extruder (not shown) pumps another resin  152  through another die  150 , and delivers the other resin to the nip N such that the other resin  152  is disposed underneath the resin  30 , becoming bonded to the outer surface  16  of substrate  14  (forming layer  160 , e.g., a tie layer), while the resin  30  becomes bonded to an outer surface of the other resin  152 . This is often advantageous, e.g., when adhesion of resin to surface  16  is poor. In some embodiments, a maleated polypropylene, or a blend of maleated polypropylene and polypropylene is used as other resin  152 , and polypropylene is used as resin  30 . 
         [0061]    In any of the above embodiments, suitable materials for forming projections, e.g., hooks  12  or stems  82 , are resins, e.g., thermoplastic resins, that provide the mechanical properties that are desired for a particular application. Suitable thermoplastic resins include polypropylene, polyethylene, acrylonitrile-butadiene-styrene copolymer (ABS), polyamide, e.g., nylon 6 or nylon 66, polyesters, e.g., polyethylene terephthalate (PET) or polybutylene terephthalate (PBT), and blends of these materials. The resin may include additives, e.g., lubricating agents, e.g., silicones or fluoropolymers, solid fillers, e.g., inorganic fillers, e.g., silica or pigments, e.g., titanium dioxide. In some embodiments, lubricating agents are employed to reduce the force required to remove molded hooks to from their respective cavities. In some embodiments, an additive is used to improve adhesion of the resin  30  to substrate  14 , e.g., an anhydride-modified linear low-density polyethylene, e.g., Plexar® PX114 available from Quantum. 
         [0062]    In any of the above embodiments, the overall moment of inertia of the nominal transverse cross-section of the substrate can be greater than 0.00020 in 4  (0.00832 cm 4 ). Examples of substrate inertial moments include 0.00065 in 4  (0.0271 cm 4 ), 0.0050 in 4  (0.208 cm 4 ), 0.040 in 4  (1.67 cm 4 ) and 0.5 in 4  (20.8 cm 4 ). 
         [0063]    In any of the above embodiments, the effective modulus of elasticity of the material from which the substrate can be greater than 100,000 psi (6.89×10 8  N/m 2 ), e.g., 250,000 psi (1.72×10 9  N/m 2 ), 750,000 psi (5.17×10 9  N/m 2 ), 1,000,000 psi (6.89×10 9  N/m 2 ) or more, e.g., 5,000,000 psi (3.45×10 10  N/m 2 ), 15,000,000 psi (1.03×10 11  N/m 2 ) or more, e.g., 30,000,000 psi (2.07×10 11  N/m 2 ). The effective modulus of elasticity of the material from which the substrate is formed is measured using ASTM E111-04 at 25° C. at fifty percent relative humidity, allowing sufficient time for moisture and temperature equilibration. 
         [0064]    In any of the above embodiments, the substrate can be, e.g., a construction material, such as wallboard, window frame, wall panel, floor tile, or ceiling tile. 
         [0065]    In any of the above embodiments, in order to improve adhesion of resin to the substrate, it is often advantageous to mold onto a substrate with an average surface roughness of greater than 1 micron, e.g., 2, 3, 4, 5 micron or more, e.g., 10 micron, as measured using ISO 4288:1996(E). 
         [0066]    In any of the above embodiments, the projections, e.g., hooks  12  or stems  82 , preferably have a density of greater than 300 projections/in 2  (46.5 projections/cm 2 ), e.g., 500 (77.5 projections/cm 2 ), 1,000 (155.0 projections/cm 2 ), 2000 (310.0 projections/cm 2 ) or more, e.g., 3,500 projections/in 2  (542.5 projections/cm 2 ). 
         [0067]    In any of the above embodiments, the substrate can be pre-heated prior to introducing substrate  14  into the gap  18 . Pre-heating is sometimes advantageously used to improve adhesion of the resin  30  (or other resin  152 ) to substrate  14 . It can also be used, when a thermoplastic resin is employed, to prevent over cooling, of the thermoplastic resin before entering the nip N. 
         [0068]    In any of the above embodiments, substrate  14  can be primed, e.g., to improve the adhesion of resin  30  (or  152 ) to substrate  14 . In some embodiments, the priming is performed just prior to introduction of substrate  14  into the gap  18 . Suitable primers include acetone, isobutane, isopropyl alcohol, 2-mercaptobenzothiazole, N,N-dialkanol toluidine, and mixtures of these materials. Commercial primers are available from Loctite® Corporation, e.g., Loctite® T7471 primer. 
         [0069]    While certain embodiments have been described, other embodiments are envisioned. 
         [0070]    While various locations of an extruder head are specifically shown in  FIG. 2 , these locations can be applied to any of the embodiments described above. 
         [0071]    As another example, while embodiments have been described in which substrates are formed from a single material, in other embodiments, substrates are formed from multiple materials. For example, the substrates can be formed of wood, metal, e.g., steel, brass, aluminum, aluminum alloys, or iron, plastic, e.g., polyimide, polysulfone, or composites, e.g., composites of fiber and resin, e.g., fiberglass and resin. 
         [0072]    As an additional example, while embodiments have been described in which the base of the fastener is formed of a single layer, in other embodiments, such bases are formed of more than a single layer of material. Referring to  FIGS. 6 and 7 , a fastener base bonded to a rigid substrate may be formed of two layers  172  and  174  ( FIG. 6 ), and each layer can be a different kind of resin. In still other embodiments, a substrate may be so formed of three layers  182 ,  184  and  186  ( FIG. 7 ). More than three layers are possible. 
         [0073]    As a further example, while substrates have been described that are T-shaped and planar in transverse cross-section, other transverse shapes are possible. Referring to  FIGS. 8A and 8B , an L-shaped substrate having hooks in which heads are directed in a single direction is shown. Still other shapes are possible. For example,  FIG. 9  shows a U-shaped substrate. 
         [0074]    While the embodiments of  FIGS. 1-3  show resin being continuously delivered to nip N, in some instances it is desirable to deliver discrete doses or charges of resin to the substrate, e.g., to reduce resin costs, so that projections are arranged on only discrete areas of the substrate. This can be done, e.g., by delivering the doses or charges through an orifice defined in an outer surface of a rotating die wheel, as described in “Delivering Resin For Forming Fastener Products,” filed Mar. 18, 2004 and assigned U.S. Ser. No. 10/803,682, the entire contents of which are incorporated by reference herein. 
         [0075]    While projections  82  of  FIG. 3A  are shown to have radiused terminal ends, in some embodiments, projections have non-radiused, e.g., castellated terminal ends, such as some of the projections described in “HOOK AND LOOP FASTENER,” U.S. Ser. No. 10/455,240, filed Jun. 4, 2003, the entire contents of which are incorporated by reference herein. 
         [0076]    Referring to  FIGS. 10 ,  11  and  12 , for example, a substrate  14  is of planar form as it proceeds through the mold station. In some cases, the substrate may be a widthwise stretchable or flexible web such as a knit loop fabric, or an elastically stretchable substrate or loop material such as is described in parent U.S. Pat. No. 7,048,818 (Krantz). In such cases, a tenter frame  33  maintains the substrate sheet in a width-wise flat condition or, when desired, stretched with as much as 50% or even 100% widthwise elastic extension depending upon the material of the substrate. As shown in  FIG. 10 , a cantilever-mounted mold roll  46   a  extends inwardly form the edge of substrate  14  or the work piece to the position where a band or bands of molded fastener stems or fully formed molded fastener hooks, are desired. 
         [0077]    Where the band or bands of fastener stems or fully formed hooks are to be applied near the edge of substrate  14 , the required nip forces are sufficiently low that rolls  46   a  and  48   a  may be supported from one end using suitably spaced bearings of a cantilever mounting. That arrangement is suggested in the solid line diagram of the mounting of mold roll  46   a  in  FIG. 10 . Where the nip pressure is greater, a cantilever support  35  for a second bearing is employed, as suggested in dashed lines in the figure. 
         [0078]    Referring to  FIGS. 10 and 11 , the operation of a molding apparatus is illustrated with substrate  14  being fed through nip N formed by mold roll  46   a  arid pressure roll  48   a . Mold roll  46   a  extends from frame  36  in a cantilevered fashion, e.g., supported from one side only, so that substrate  14  of width, W.sub.2, greater than the width, W.sub.3, of mold roll  46   a  can be processed through nip N without interfering with frame  36 . Typically mold roll  46  has width W.sub.3 of less than approximately 2 ft. The cantilevered support of one or the rolls leaves ah open end of nip N to allow workpieces of substantially greater than either roll  46   a  or  48   a  to pass through nip N without interfering with support frame  36 . As substrate  14  moves through nip N, cavities  37  of mold roll  46   a  are filled, as described below, with molten thermoplastic resin, e.g., polypropylene, to form engageable elements, e.g., hooks which are deposited in a relatively narrow band onto a portion of substrate  14 . The initially molten thermoplastic resin adheres the base of each hook stem to substrate  14  as the thermoplastic resin solidifies, in an in situ bonding action. 
         [0079]    The amount of molten thermoplastic resin delivered to the mold roll determines whether the hooks will form an integral array of thermoplastic resin joined together by a thin base layer which is adhered to the surface of the preformed carrier sheet or substrate  14  or whether the hooks will be separate from one anther, individually adhered to the carrier. For example, as shown in  FIG. 4 , a thin layer of thermoplastic resin forms a base layer  122   a  integral with the array  125   c  of hooks  124   c.    
         [0080]    However, by reducing the amount of thermoplastic resin delivered to the mold roll, joining base layer  122   a  can be eliminated so that the base of each molded fastener stem is in situ bounded substrate  14  without thermoplastic resin joining hooks  124   c  together. 
         [0081]    Referring now to  FIG. 12 , an example of delivery of molten thermoplastic resin to the mold roll  46   a  to form fastener elements  124   c  on substrate  14  will be described. Molten thermoplastic resin is delivered to mold roll  46   a  by extruder  42 . Delivery head  42   a  of extruder  42  is shaped to conform with a portion of the periphery of mold roll  46   a  to form base layer  122   a  and to prevent extruded thermoplastic resin from escaping as it is forced into hook cavities  37  of rotating (counterclockwise) mold roll  46   a . Rotation of mold roll  46   a  brings base portions of thermoplastic resin-filled cavities  37  into contact with substrate  14  and the thermoplastic resin is forced (by pressure roll  48   a  ( FIG. 10 )) to bond to the surface of substrate  14 . In the case of porous or fibrous substrates, carrier sheets or workpieces, the thermoplastic resin solidifies, portions which have partially penetrated the surface adhere to substrate  14  with further rotation of mold roll  46   a  partially solidified molded hooks  124   c  or stems are extracted from mold cavities  37  leaving a band of hooks or stems projecting from substrate  14 . By adjusting the space between head  42   a  and mold roll  46 , the volume of molten thermoplastic resin delivered, and the speed rotation of mold roll  46   a , an amount of thermoplastic resin beyond the capacity of mold cavities  37  can be delivered to mold roll  46   a . This additional thermoplastic resin resides on the periphery of mold roll  46   a  and is brought into contact with substrate  14  to form base layer  122   a  of thermoplastic resin from which the stems of the engaging elements  124   c  extend. In dashed lines, an alternative method of delivering the molten resin to the mold roll, as described previously above, is also suggested. 
         [0082]    It will be realized that the apparatus of  FIGS. 10-12  do not require that substrate  14  be flexible. It may indeed be a rigid workpiece, for instances it may be a construction material such as preformed building siding, roofing material, or a structural member, fed through the molding station on appropriate conveyors. The apparatus of all of the embodiments may be incorporated in a manufacturing line, in which the substrate, carrier or workpiece is a preform, upon which further actions are taken other than in situ bonding of fasteners or fastener stems occurs. The manufacturing line may be, e.g., for manufacture of building siding, roof shingles or packaging sheet or film. 
         [0083]    There are other ways to form e.g. separated parallel linear bands or discrete, disconnected islands of hooks on the above-described substrates within certain broad aspects of the present invention. For example, at dispersed, selected locations across the width of a traveling preformed substrate, e.g. a material defining hook-engageable loops, discrete separate molten resin deposits of the desired form, e.g. of x, y-isolated islands, or in spaced apart parallel bands, may be deposited upon the surface structure of the substrate. Following this, upper portions of the resin deposits, while still molten, or after being reheated by an intense localized flame line, are molded into fastener stems by mold cavities that are pressed against the resin deposits. For instance, at selected widthwise separated locations along a deposit line, as the substrate transits the line, discrete island-form deposits are made; at selected locations. Immediately, with the resin still molten, or after heat activation, the substrate is introduced into a molding nip, formed by a mold roll and a pressure roll. The mold roll; for instance, defines tiny fixed hook fastener cavities as described above, or smaller fastener features, e.g. of less than 0.005 inch height, or similarly shallow cavities for tiny stem preforms, that are aligned to press down upon the resin deposits under conditions in which nip pressure causes the molten resin to enter the cavities at the base of the stem portion of the cavities, and fill the molds, and be molded into a localized dense array of stem preforms or into a localized dense array of fully formed loop-engageable molded hooks. With appropriate amounts of resin in the deposits, a base layer common to all of the molded stems of a discrete island deposit can be formed by the mold roll surface, as may be desired. The mold pressure, simultaneously with the molding, causes the resin to bond firmly to the surface structure of the preformed carrier, effecting in situ lamination, Where the preformed substrate has a fibrous or porous makeup, as with hook-engageable loop material, the nip pressure causes the resin to commingle with the top fibers or other structure that define the surface structure of the substrate, without penetrating the full depth of the substrate. Thus the opposite side of me substrate can remain pristine, free of the molding resin, and, if the opposite surface of the preformed web defines a uniform surface of hook-engageable loops across the full width of the article, the effectiveness of those loops can be preserved while the molded stems or fully molded hooks are molded and in situ bonding occurs. 
         [0084]    With such arrangements it will be understood that the regions of the substrate between the separated islands remain free of the resin from which the hooks or stem preforms are molded. Thus, in the case of elastically stretchy substrate webs or carrier sheet preforms, whether of plain preformed elastomer sheet, or of stretchy hook-engageable loop material, the resin-free regions enable the web to be elastically stretchy, while flexibility of the article in both orthogonal (X,Y) directions in the plane of the web is achieved. Where the preformed carrier web is a non-stretchy, but flexible material, such as a bi-directionally stabilized knit loop product having hook-engageable loops on both sides, the regions between the separated islands enable the finished article to be simply flexible in both X and Y directions in the plane of the fabric. 
         [0085]    In certain embodiments, rather than locating discrete regions of hook cavities on the mold roll, in positions to register with a pre-arranged pattern of resin deposits, the mold roll may simply have an array of mold cavities entirely occupying the mold surface of the roll, or may have, such mold cavities in narrow bands separated by enlarged spacer rings or cross-wise extending ridges, as described above. 
         [0086]    Still other embodiments, are within the scope of the claims that follow.

Technology Classification (CPC): 1