Sheet material for forming the loop portion for hook and loop fasteners

Claim 2

A method for forming a sheet material (10, 40, 60) according to claim 1 wherein said forming step comprises the steps of: providing first and second generally cylindrical corrugating members (27, 28; 44, 45; 64, 65) each having an axis and including a plurality of spaced ridges (28, 46, 66) defining the periphery of the corrugating member, the ridges (28, 46, 66) having outer surfaces and defining spaces between said ridges (28, 46, 66) adapted to receive portions of the ridges (28, 46, 66) of the other corrugating member in meshing relationship with the sheet of fibers (16, 38, 59) therebetween; mounting the corrugating members (27, 28; 44, 45; 64, 65) in axially parallel relationship with portions of the ridges (28, 46, 66) in meshing relationship; rotating at least one of the corrugating members (27, 28; 44, 45; 64, 65); feeding the sheet of fibers (16, 38, 59) between the meshed portions of the ridges (28, 46, 66) to generally conform the sheet of fibers (16, 38, 59) to the periphery of the first corrugating member (27, 44, 64) and form the arcuate portions (20, 54, 69) of the fibers (16, 38, 59) in the spaces between the ridges (28, 46, 66) of the first corrugating member (27, 44, 64) and the anchor portions of the sheet of fibers (16, 38, 59) along the outer surfaces of the ridges (28, 46, 66) of the first corrugating member; and retaining the formed sheet of fibers (16, 38, 59) along the periphery of the first corrugating member (27, 44, 64) after movement past the meshing portions of the ridges (28, 46, 66); wherein said bonding step occurs with the formed sheet of fibers (16, 38, 59) along the periphery of the first corrugating member (27, 44, 64) after movement past the meshing portions of the ridges (28, 46, 66); and said method further includes separating the sheet material (10, 40, 60) from the first corrugating member (27, 44, 64).

Claim 3

A method according to claim 2 wherein in said feeding step the sheet of fibers (16, 38, 59) fed between the meshed portions of the ridges (28, 46, 66) of the corrugating members (27, 28; 44, 45; 64, 65) is in the form of a non woven web.

Claim 4

A method according to claim 2 wherein said ridges (28, 46, 66) are elongate and parallel, and in said feeding step the sheet of fibers (16, 38, 59) fed between the meshed portions of the ridges (28, 46, 66) of the corrugating members (27, 28; 44, 45; 64, 65) is in the form of a non woven web having a plurality of the fibers (16, 38, 59) projecting generally at a right angle to the ridges (28, 46, 66).

Claim 5

A method according to claim 2 wherein said ridges (28, 66) are elongate and parallel and are oriented at an angle in the range of 0 to 45 degrees with respect to the axes of the corrugating members (27, 28; 64, 65), and said feeding step includes the steps of: providing the fibers (16, 59) in the form of yarns in the range of 50 to 300 denier; distributing the yarns to provide a sheet of generally uniformly distributed fibers (16, 59); and feeding the sheet of fibers (16, 59) between the meshed ridges (28, 66) of the gear with all of the fibers (16, 59) extending generally at a right angle to the axes of the corrugating members (27, 28; 64, 65).

Claim 6

A method according to claim 2 wherein said ridges (28, 66) are oriented at an angle of about 5 degrees with respect to the axes of the corrugating members (27, 28; 64, 65), and said feeding step includes the steps of; providing the fibers (16, 59) in the form of yarns in the range of 50 to 300 denier; distributing the yarns to provide a sheet of generally uniformly distributed fibers (16, 59); and feeding the sheet of fibers (16, 59) between the meshed portions of the ridges (28, 66) with all of the fibers (16, 59) extending generally at a right angle to the axes of the corrugating members (27, 28; 64, 65).

Claim 7

A method according to claim 1 further including the step of printing the backing (12, 43, 63) along one of its surfaces prior to said bonding step.

Claim 8

A method according to claim 1 wherein the backing (12, 43, 63) and the fibers (16, 38, 59) comprise the same thermoplastic material, and said bonding step comprises fusing the fibers (16, 38, 59) to the backing (12, 43, 63) at the bonding locations (18, 68).

Claim 9

A method according to claim 1 wherein said bonding step comprises adhesively bonding the fibers (16, 38, 59) to the backing (12, 43, 63) at the bonding locations (18, 68).

Claim 10

A sheet material made by the method of claim 1.

Claim 11

A sheet material (10, 40, 60) according to claim 10 wherein the fibers (16, 38, 59) in said arcuate portions (20, 54, 69) project to about the same height above said front surface (13, 58), and said height is at least one third the distance between said bonding locations (18, 68).

Claim 12

A sheet material (10, 40) according to claim 10 wherein said bonding locations (18) are elongate, generally parallel, and continuous in one direction along said front surface (13) of said backing (12, 43) to form continuous rows of said arcuate portions (20, 54) along said front surface (13) of said backing (12, 43).

Claim 13

A sheet material (60) according to claim 10 wherein said bonding locations (68) are elongate, generally parallel, and in a regular pattern of discontinuous lengths to to form a pattern of discontinuous rows of said arcuate portions (69) along said front surface (58) of said backing (63).

Claim 14

A sheet material (10, 40, 60) according to claim 10 wherein said bonding locations (18, 68) are elongate and generally parallel, and said fibers (16, 38, 59) are disposed in various directions with respect to said parallel bonding locations (18, 68).

Claim 15

A sheet material (10, 40, 60) according to claim 10 wherein said bonding locations (18, 68) are elongate and generally parallel, and said fibers (16, 38, 59) are disposed in various directions with respect to said parallel bonding locations (18, 68) with the majority of said fibers (16, 38, 59) extending in directions generally at right angles to said bonding locations (18, 68).

Claim 16

A sheet material (10, 40, 60) according to claim 10 wherein said bonding locations (18, 68) are elongate and generally parallel, and essentially all of said fibers (16, 38, 59) extend in directions generally at right angles to said spaced generally parallel bonding locations (18, 68).

Claim 17

A sheet material (10, 40, 60) according to claim 10 wherein said fibers (16, 38, 59) have a basis weight in the range of 10 to 75 grams per square meter measured along said front surface (13, 58) of said backing (12, 43, 63), the fibers (16, 38, 59) in said arcuate portions (20, 54, 69) project to about the same height above said front surface (13, 58), and said height is in the range of one half to one and one half the distance between said bonding locations (18, 68).

Claim 18

A sheet material (10, 40, 60) according to claim 10 wherein said backing (12, 43, 63) is a polymeric film material less than 0.013 centimeters thick.

Claim 19

A sheet material (10, 40, 60) according to claim 10 wherein said backing (12, 43, 63) is a polymeric film material and has printing along one of said surfaces, said printing being visible through said arcuate portions (20, 54, 69) of said fibers (16, 38, 59).

Claim 20

A sheet material (10, 40, 60) according to claim 10 wherein said backing (12, 43, 63) and said fibers (16, 38, 59) comprise the same thermoplastic material, and said fibers (16, 38, 59) are fused to said backing (12, 43, 63) at said bonding locations (18, 68).

Claim 21

A sheet material (10, 40, 60) according to claim 10 wherein said backing (12, 43, 63) and said fibers (16, 38, 59) are adhesively bonded to said backing (12, 43, 63) at said bonding locations (18, 68).

Claim 22

A disposable garment including a fastener comprising releasably engageable hook and loop portions, said loop portion comprising: a backing (12, 43, 63) having front and rear major surfaces (13 and 14, 58); and a multiplicity of fibers (16, 38, 59) having portions bonded to said backing (12, 43, 63) along said front surface (13, 58) at spaced bonding locations (18, 68) to form arcuate portions (20, 54, 69) of said fibers (16, 38, 59) projecting from the front surface (13, 58) of said backing (12, 43, 63) between said bonding locations (18, 68), said arcuate portions (20, 54, 69) having a height from said backing (12, 43, 63) of less than about 0.64 centimeters (0.250 inch), and said fibers (16, 38, 59) having a basis weight in the range of 5 to 200 grams per square meter measured along said first surface (13, 58) to provide sufficient open area between said fibers (16, 38, 59) along said arcuate portions (20, 54, 69) to afford ready engagement of said fibers (16, 38, 59) along said arcuate portions (20, 54, 69) by the hook portion of said fastener.

Claim 23

A disposable garment according to claim 22 wherein said garment further includes an outer polymeric layer and said rear surface (14) of said backing (12, 43, 63) is adhered to said outer polymeric layer.

Claim 24

A disposable garment according to claim 22 in wherein said disposable garment further includes an outer polymeric layer with a portion of said outer polymeric layer providing said backing (12, 43, 63) for said loop portion.

Claim 25

An abrasive disk comprising a layer having first and second surfaces, an abrasive material adhered along said first surface, and a loop portion for a hook and loop fastener attached along said second surface, said loop portion comprising: a backing (12, 43, 63) having front and rear major surfaces (13 and 14, 58) with said rear surface attached along the second surface of said layer; and a multiplicity of fibers (16, 38, 59) having portions bonded to said backing (12, 43, 63) along said front surface (13, 58) at spaced bonding locations (18, 68) to form arcuate portions (20, 54, 69) of said fibers (16, 38, 59) projecting from the front surface (13, 58) of said backing (12, 43, 63) between said bonding locations (18, 68), said arcuate portions (20, 54, 69) having a height from said backing (12, 43, 63) of less than about 0.64 centimeters (0.250 inch), and said fibers (16, 38, 59) having a basis weight in the range of 5 to 200 grams per square meter measured along said front surface (13, 58) to provide sufficient open area between said fibers (16, 38, 59) along said arcuate portions (20, 54, 69) to afford ready engagement of said fibers (16, 38, 59) along said arcuate portions (20, 54, 69) by the hook portion of said fastener.