Method for manufacturing a forming surface connection and forming surface connection

Abstract

The manufacturing method of the shaped surface connector (1, 2, 3) of the present application uses a thermoplastic resin having a melt flow rate of 20 g / 10 min or more and 60 g / 10 min or less, and a flexural modulus of 1000 MPa or more and 2300 MPa or less as a synthetic resin for forming the shaped surface connector (1, 2, 3). Thus, a fitting element (10, 30, 40) in which the top end surface (12a) of the fitting head portion (12, 32, 42) is flat, and at least a part of the back side base end surface (12b, 32b, 42b) of the fitting head portion (12, 32, 42) has an angle of 70° or more and 110° or less with respect to the height direction of the stem portion (11) can be stably formed, and therefore, a shaped surface connector (1, 2, 3) having a high peeling strength and a good skin touch can be obtained.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a shaped surface connector having a plurality of engaging elements provided on a substrate portion, and a shaped surface connector manufactured by the method thereof. Background Technology

[0002] Traditionally, it is known that face connector products are used in pairs, consisting of a ring member (female face connector) with multiple interlocking rings and a male molded face connector that can be detached from the ring member. For example, a male molded face connector manufactured by molding synthetic resin is formed by having multiple male engaging elements in the shape of mushrooms or the like erected on the upper surface of a flat substrate.

[0003] Face connectors with such a masculine shape are currently used in a wide variety of products, and are mostly used in products that are related to body assembly and disassembly, such as disposable diapers, diaper bibs for infants and young children, protective devices for joints such as protecting hands and feet, waistbands (back pain belts), gloves, etc.

[0004] In addition, an example of a method for manufacturing a face connector having multiple male-shaped engaging elements in the shape of a mushroom or the letter J is described, for example, in Japanese Patent No. 3515117 (corresponding to Japanese Patent No. 1: Japanese Patent No. 8-508910) and Japanese Patent No. 4168182 (corresponding to Japanese Patent No. 2002-504006).

[0005] In the manufacturing methods described in Patent Documents 1 and 2, a primary forming process is first performed, in which a primary molded body is formed having a flat substrate portion and a plurality of primary rod portions (temporary elements) erected on the substrate portion. Then, a secondary forming process is performed, in which the obtained primary molded body is passed between pairs of upper and lower calendering rolls (heated pressing rolls), thereby heating and pressing a portion of the primary rod portion formed in the primary molded body.

[0006] Through this secondary forming process, the primary rod (temporary element) is transformed into a mushroom-shaped engaging element having a rod and an engaging head integrally formed on the rod, or a letter J-shaped engaging element having a rod and an engaging head extending curvedly from the upper end of the rod. Therefore, it is possible to easily manufacture a face connector having multiple engaging elements in a predetermined shape.

[0007] In particular, in the manufacturing method of Patent Document 1, during the secondary forming process, the set speed at which the primary forming body passes between the upper and lower calendering rolls, the gap size through which the primary forming body passes, and the heating capacity of the calendering roll surface are controlled to manufacture a surface connector with a plurality of mushroom-shaped engaging elements having a slightly concave top surface (upper end surface) of the engaging head. Patent Document 1 explains that the engaging elements have such a shape that they exhibit excellent engaging force in the shear direction relative to the ring member, and can be manufactured inexpensively.

[0008] In the manufacturing method of Patent Document 2, a plurality of grooves (valve portions) formed along one direction are provided on the surface of the upper calender roll used in the secondary forming process. By using a calender roll with such a plurality of grooves to perform the secondary forming process, a surface connector can be manufactured from the primary rod portion of the primary formed body. This surface connector has a plurality of engaging elements bent into the shape of the letter J, or a plurality of engaging elements whose engaging head is formed longer in the mechanical direction and whose top surface (upper end surface) has a plurality of straight recesses. Patent Document 2 explains that by having a calender roll with a plurality of grooves in the secondary forming process, engaging elements with enhanced engaging properties relative to the ring member are obtained.

[0009] Existing technical documents

[0010] Patent documents

[0011] Patent Document 1: Japanese Patent No. 3515117

[0012] Patent Document 2: Japanese Patent No. 4168182 Summary of the Invention

[0013] The problem the invention aims to solve

[0014] As described above, in the manufacturing methods of Patent Document 1 and Patent Document 2, by employing specific forming conditions and the shape of the calendering roll in the secondary forming process, the engaging element (especially the engaging head) is formed into a characteristic shape, thereby improving the peel strength (engagement strength) of the ring member relative to the formed surface connector. However, currently, surface connector products are used in a wide variety of goods as described above, and some goods require higher strength. Therefore, there is a need to develop formed surface connectors with higher peel strength relative to the ring member.

[0015] Furthermore, in the molded surface connectors manufactured by the manufacturing methods of Patent Document 1 and Patent Document 2, the upper end faces of each engaging element are not formed flat. Therefore, it is difficult to say that the skin feel (tactile sensation) of the upper surface side of the connector with multiple engaging elements in the molded surface connector is good, and there is room for improvement.

[0016] The present invention was made in view of the above-mentioned prior art problems, and its object is to provide a method for manufacturing a shaped surface connector that can form an engaging element into a shape that is easy to obtain high peel strength and can obtain a good skin feel on the upper surface side of the connector, and a shaped surface connector manufactured by the manufacturing method.

[0017] Solution for solving the problem

[0018] To achieve the above objectives, the manufacturing method of the first aspect of the present invention is a method for manufacturing a molded surface connector made of synthetic resin. The molded surface connector has a plurality of engaging elements, each engaging element comprising: a rod portion erected from a base material portion; and an engaging head integrally formed on the rod portion. The manufacturing method includes: a primary molding step in which a primary molded body having the base material portion and a plurality of temporary elements erected on the base material portion is formed; and a secondary molding step in which at least a portion of the temporary elements of the primary molded body is heated, and the at least a portion is pressed from above to form the molded surface connector. The most important feature of this manufacturing method is that it includes using a thermoplastic resin with a melt flow rate of 20 g / 10 min or more and 60 g / 10 min or less, and a flexural modulus of elasticity of 1000 MPa or more and 2300 MPa or less as the synthetic resin.

[0019] The manufacturing method of the molded surface connector of the second aspect of the present invention is a method for manufacturing a molded surface connector made of synthetic resin. This molded surface connector has a plurality of engaging elements, each engaging element comprising: a rod portion erected from a base material portion; and an engaging head integrally formed on the rod portion. The manufacturing method includes the following steps: a primary molding step, in which a primary molded body having the base material portion and a plurality of temporary elements erected on the base material portion is formed; and a secondary molding step, in which the primary molded body is heated. The manufacturing method is characterized by forming the temporary element by pressing at least a portion of it from above, thereby forming the shaped surface connector. The most important feature of this manufacturing method is that it includes: using a thermoplastic resin with a melt flow rate of 1 g / 10 min or more and 60 g / 10 min or less, and a flexural modulus of 1600 MPa or more and 3000 MPa or less as the synthetic resin; and in the secondary forming process, pressing the temporary element from above using a pressing roller with a diameter of 300 mm or more and 500 mm or less.

[0020] Furthermore, in the manufacturing methods of the molded surface connectors of the first and second forms, it is preferable that, in the secondary molding process, at least a portion of the temporary element is heated at a heating temperature that is at least 50°C lower than the melting point of the synthetic resin and at least 20°C lower than the melting point of the synthetic resin, and the temporary element is pressed from above, thereby forming the engaging element whose height dimension is at least 20 μm smaller than the height dimension of the temporary element and at least 80 μm smaller.

[0021] Next, the first embodiment of the molded surface connector of the present invention is a molded surface connector made of synthetic resin, which has a plurality of engaging elements, each of which includes: a rod portion that stands upright from a base material portion; and an engaging head integrally formed on the rod portion. The most important feature of the molded surface connector made of synthetic resin is that the engaging head has at least: a top surface that is exposed upward and is formed flat; and a back base end surface disposed on the opposite side of the top surface and extending outward from the boundary between the engaging head and the rod portion. At least a portion of the back base end surface of the engaging head has an angle of 70° or more and 110° or less relative to the height direction of the rod portion.

[0022] Furthermore, in the first embodiment of the shaped surface connector, it is preferable that the engaging head has a circular shape when the shaped surface connector is viewed from above, and when observing a cross section parallel to the height direction of the engaging element and including the central axis portion of the rod, at least a portion of the back base end face of the engaging head has a straight plane, and the plane of the back base end face has a length of 20 μm or more in the cross section.

[0023] The second aspect of the molded surface connector of the present invention is a molded surface connector made of synthetic resin. The molded surface connector has a plurality of engaging elements, each of which includes: a rod portion that stands upright from a base material portion; and an engaging head integrally formed on the rod portion. The most important feature of the molded surface connector is that the engaging head has at least: a top surface that is exposed upward; and a back base end surface disposed on the opposite side of the top surface and extending outward from the boundary between the engaging head and the rod portion. Furthermore, the engaging head has an elliptical shape when the molded surface connector is viewed from above, and at least a portion of the back base end surface of the engaging head has an angle of 120° or more relative to the height direction of the rod portion.

[0024] The effects of the invention

[0025] In order to improve the peel strength of the manufactured molded surface connector and enhance the skin-touch feel of the upper surface side of the molded surface connector, the inventors conducted in-depth research on the manufacturing method of the molded surface connector. As a result, they discovered that among the various properties of the synthetic resin forming the molded surface connector, the melt flow rate (hereinafter sometimes abbreviated as MFR) and flexural modulus are very important, as these properties have a significant impact on the shape of the engaging element. Through further repeated experiments and research, the present invention was completed.

[0026] That is, the manufacturing method of the molded surface connector of the first aspect of the present invention includes: a primary molding step, in which a primary molded body having a base portion and a plurality of temporary elements erected on the base portion is formed; and a secondary molding step, in which at least a portion of the temporary elements of the primary molded body obtained is heated and pressed from above to form the molded surface connector. Moreover, in the manufacturing method of the first aspect, a thermoplastic resin is used as the synthetic resin (material) for forming the molded surface connector, the thermoplastic resin having an MFR of 20 g / 10 min or more and 60 g / 10 min or less, preferably 40 g / 10 min or more and 60 g / 10 min or less, and a flexural modulus of elasticity of 1000 MPa or more and 2300 MPa or less, preferably 1000 MPa or more and 1500 MPa or less.

[0027] By using a thermoplastic resin with an MFR and flexural modulus within the range described above to form the molded surface connector, it is possible to smoothly and stably manufacture a molded surface connector having multiple engaging elements. These multiple engaging elements have thin and flat engaging heads, and the back-side base end face extending outward from the rod portion of the engaging head is formed at an angle of 70° or more and 110° or less relative to the vertical direction.

[0028] The engaging elements of the manufactured shaped surface connector have the aforementioned characteristic shapes, which prevent the buckle on the engaging head from easily detaching from the engaging element when the ring member is engaged with the shaped surface connector. Therefore, the peel strength (engagement strength) of the shaped surface connector relative to the ring member can be easily improved. Furthermore, the top surface of the engaging head can be formed flat, thus the shaped surface connector can have a good skin-touch feel on the upper surface side of the connector.

[0029] Next, in the manufacturing method of the molded surface connector of the second aspect of the present invention, a primary molding process and a secondary molding process are performed, and a thermoplastic resin with an MFR of 1 g / 10 min or more and 60 g / 10 min or less, and a flexural modulus of 1600 MPa or more and 3000 MPa or less is used as the synthetic resin (material) for forming the molded surface connector. Moreover, in the manufacturing method of the second aspect, in the secondary molding process, a pressing roller with a diameter of 300 mm or more and 500 mm or less, which can heat the roller surface to a predetermined temperature, is used to press the temporary element from above.

[0030] The molding surface connector is formed using a thermoplastic resin having an MFR and flexural modulus within the range described above. Furthermore, a press roller with a diameter of 300 mm or more and 500 mm or less is used in the secondary molding process, thereby enabling the smooth and stable manufacture of a molding surface connector having multiple engaging elements. These multiple engaging elements have thin engaging heads that are elliptical when the molding surface connector is viewed from above, and the back base end face extending outward from the rod portion of the engaging head is formed at an angle of 120° or more relative to the vertical direction.

[0031] By manufacturing the shaped surface connector with each engaging element having the aforementioned characteristic shape, when the ring member is engaged with the shaped surface connector, the buckle hooked to the engaging element's engaging head is less likely to detach from the engaging element. Therefore, the peel strength (engagement strength) of the shaped surface connector relative to the ring member can be easily improved. Furthermore, the top surface of the engaging head can be formed flat, thus obtaining a shaped surface connector with a pleasant skin feel.

[0032] In the manufacturing methods of the first and second embodiments of the present invention, in the secondary molding process, at least a portion of the temporary element is heated at a heating temperature that is at least 50°C lower than the melting point of the synthetic resin and at least 20°C lower than the melting point of the synthetic resin. The temporary element is then pressed from above, thereby forming an engaging element whose height dimension is at least 20 μm smaller than the height dimension of the temporary element and at least 80 μm smaller. By performing the secondary molding process (secondary processing) under such conditions, the engaging heads of each engaging element can be more stably shaped into the characteristic shapes described above in the first or second embodiment.

[0033] The first embodiment of the present invention provides a shaped surface connector having a plurality of engaging elements, each engaging element comprising: a rod portion erected from a base material portion; and a disc-shaped engaging head integrally formed on the rod portion. Furthermore, the engaging head has at least: a top surface exposed upwards and formed flat; and a ring-shaped back base surface disposed vertically in the direction opposite to the top surface, facing the base material portion, and extending outwards from the boundary between the engaging head and the rod portion. At least a portion of the back base surface of the engaging head has an angle of 70° or more and 110° or less relative to the height direction (vertical direction) of the rod portion, preferably an angle of 70° or more and 90° or less.

[0034] In the shaped surface connector having such an engaging element, the back-side base end face of the engaging head is formed at an angle within a predetermined range relative to the vertical direction. Therefore, when the multiple loops of the ring member are engaged with the shaped surface connector, the loops hooked to the engaging head of the engaging element are less likely to detach from the engaging element. Thus, the shaped surface connector of the present invention can have high peel strength relative to the ring member. Furthermore, the top surface of the engaging head is formed flat, thus a shaped surface connector with a good skin feel can be obtained.

[0035] Furthermore, in the first embodiment of the shaped surface connector, the engaging head of the engaging element has a circular shape when viewed from above, and when observing a cross-section parallel to the height direction of the engaging element and including the central axis portion of the rod, at least a portion of the back-side base end face of the engaging head has a straight plane. In this case, the plane of the back-side base end face has a length of 20 μm or more in the aforementioned cross-sectional view, preferably 40 μm or more.

[0036] The loop fasteners commonly used in disposable diapers, diaper bibs, etc., are mostly 10μm to 15μm in diameter. In the first embodiment, the engaging head is circular when viewed from above, and the plane of the dorsal base end face, as described above, has a length of 20μm or more. This allows the loop fasteners of typical loop fasteners in disposable diapers, etc., to easily hook onto the disc-shaped engaging head of the engaging element. Furthermore, the hooked loop fastener can be stably held onto the engaging element, thus preventing it from easily detaching from the engaging element.

[0037] In this case, the plane of the back-side base end face in the engaging head preferably has a length of 90 μm or less in the cross-sectional view described above. This prevents the engaging head from becoming too large and allows the ring member to engage smoothly with the forming surface connector.

[0038] The second embodiment of the molded surface connector of the present invention has a plurality of engaging elements, each comprising: a rod portion that stands upright from a base material portion; and a disc-shaped engaging head integrally formed on the rod portion. Furthermore, the engaging head has at least: a top surface that is exposed upwards and formed flat; and a ring-shaped back base end surface disposed vertically in the direction opposite to the top surface, facing the base material portion, and extending outwards from the boundary between the engaging head and the rod portion. The engaging head has an elliptical shape when the molded surface connector is viewed from above. Moreover, at least a portion of the back base end surface of the engaging head has an angle of 120° or more relative to the height direction (vertical direction) of the rod portion.

[0039] In the molded surface connector having the aforementioned engaging element, the back-side base end face of the engaging head is formed at an angle of 120° or more relative to the vertical direction. Therefore, it is easy to form a flat top surface of the engaging head with a relatively wide area. This results in a pleasant tactile feel on the upper surface of the connector in the molded surface connector. Furthermore, although the back-side base end face of the engaging head is formed at the aforementioned angle, the engaging head has an elliptical shape when viewed from above. This prevents the loops of the engaging head from easily detaching from the engaging element at the long axis side when the multiple loops of the ring member are engaged with the molded surface connector. Therefore, the molded surface connector of the present invention can have high peel strength relative to the ring member. Attached Figure Description

[0040] Figure 1 This is a perspective view showing the shaped surface connector according to the first embodiment of the present invention.

[0041] Figure 2 Viewed from the front-to-back direction (mechanical direction). Figure 1 The front view of the engaging element of the shaped surface connector shown.

[0042] Figure 3 Viewed from above Figure 1 A top view of the engaging element of the shaped surface connector shown.

[0043] Figure 4 This is a schematic diagram illustrating the manufacturing apparatus for the forming surface connector according to the first embodiment.

[0044] Figure 5 It is a schematic representation Figure 4 A perspective view of the cylindrical body used in the forming device of the manufacturing apparatus shown.

[0045] Figure 6 This is a perspective view showing a temporary element of a one-piece molded body obtained in the first embodiment.

[0046] Figure 7 This is a perspective view of the engaging element of the molded surface connector in the first modified example of the first embodiment.

[0047] Figure 8 Viewed from the front-to-back direction (mechanical direction). Figure 7 The front view of the locking element shown.

[0048] Figure 9 This is a cross-sectional view of the engaging element of the forming surface connector in the second variation of the first embodiment, with a section orthogonal to the front-back direction (mechanical direction).

[0049] Figure 10 This is a perspective view showing the shaped surface connector according to the second embodiment of the present invention.

[0050] Figure 11 Viewed from the front-to-back direction (mechanical direction). Figure 10 The front view of the engaging element of the shaped surface connector shown.

[0051] Figure 12 Viewed from above Figure 10 A top view of the engaging element of the shaped surface connector shown.

[0052] Figure 13 This is a perspective view showing a temporary element of a one-piece molded body obtained in the second embodiment.

[0053] Figure 14 This is a perspective view of the engaging element of the shaped surface connector in Comparative Example 1.

[0054] Figure 15 Viewed from the front-to-back direction (mechanical direction). Figure 14 The front view of the locking element shown.

[0055] Figure 16This is a perspective view of the engaging element of the shaped surface connector in Comparative Example 2.

[0056] Figure 17 Viewed from the front-to-back direction (mechanical direction). Figure 16 The front view of the locking element shown.

[0057] Figure 18 Viewed from above Figure 16 The top view of the engaging element shown.

[0058] Figure 19 This is a schematic diagram of the test piece used in the peel strength test of the face joint.

[0059] Figure 20 This is an explanatory diagram illustrating the peel strength test. Detailed Implementation

[0060] The following is a reference to the appendix. Figure 1 The preferred embodiments of the present invention will be described in detail below. Furthermore, the present invention is not limited to the embodiments described below; various modifications can be made as long as the structure is substantially the same as that of the present invention and achieves the same effect. For example, in the following embodiments, the number, arrangement position, and formation density of the engaging elements disposed on the substrate portion of the forming surface connector are not particularly limited and can be arbitrarily changed.

[0061] (First Embodiment)

[0062] Figure 1 This is a perspective view showing the shaped surface connector of the first embodiment. Figure 2 and Figure 3 These are the front view and top view of the engaging element in the first embodiment.

[0063] Furthermore, in the following description, the front-back direction for the forming surface connector and the primary molded body refers to the length direction of the forming surface connector and the primary molded body that are to be formed longer as described later. In addition, it refers to the first direction along the mechanical direction (MD) of conveying the forming surface connector or the primary molded body in the manufacturing process of the forming surface connector.

[0064] The left-right direction refers to the width direction, which is orthogonal to the length direction and runs along the upper (or lower) surface of the substrate portion of the forming surface connector. In this case, the left-right direction and the width direction can also be referred to as the orthogonal direction (CD) or the second direction, which is orthogonal to the mechanical direction (MD). The up-down direction (thickness direction) refers to the height direction (height direction of the engaging element), which is orthogonal to the length direction and runs along the upper (or lower) surface of the substrate portion of the forming surface connector.

[0065] The shaped surface connector 1 of the first embodiment is used as described below. Figure 4 The manufacturing apparatus 20 shown, which includes a forming device 21 and a heating and pressing device 28, is manufactured into a rectangular shape that is longer in the mechanical direction MD when viewed from above. Furthermore, the length (dimension in the mechanical direction MD) and width (dimension in the orthogonal direction CD) of the forming surface connector 1 of the present invention are not particularly limited and can be arbitrarily changed by cutting the forming surface connector 1, etc. Additionally, the forming surface connector 1 may have a shape other than a rectangle when viewed from above.

[0066] The molded surface connector 1 of the first embodiment is formed of a thermoplastic resin with a modulus of elasticity (MFR) and a flexural modulus of elasticity (Flexural modulus) within a predetermined range, as described later. In this case, the synthetic resin forming the molded surface connector 1 can be, for example, thermoplastic resins such as polypropylene, polyester, nylon, polybutylene terephthalate, or copolymers thereof. In particular, the molded surface connector 1 of the first embodiment is formed of polypropylene.

[0067] The shaped surface connector 1 has: a thin, flat substrate portion 9; and a plurality of engaging elements 10, which stand vertically on the upper surface of the substrate portion 9 and have a mushroom-shaped form. The substrate portion 9 is formed to be relatively long along the mechanical direction MD during the manufacture of the shaped surface connector 1. In addition, the substrate portion 9 has a predetermined thickness to obtain appropriate strength, and both the upper and lower surfaces of the substrate portion 9 are flat and formed to be parallel to each other.

[0068] The engaging element 10 of the first embodiment includes: a rod portion 11 that stands upright from the base material portion 9; and a disc-shaped or dish-shaped engaging head 12 that is integrally formed on the rod portion 11 and is formed to extend outward from the entire circumference of the upper end of the rod portion 11.

[0069] The rod portion 11 is formed to extend in a direction orthogonal to the upper surface of the base material portion 9. Furthermore, the rod portion 11 has a frustum-shaped form in which the area of ​​the cross-section orthogonal to the vertical direction increases with increasing proximity to the base material portion 9. Moreover, in this invention, the shape of the rod portion 11 is not limited to a frustum shape; for example, it can also be a frustum shape such as a square pyramid, a cylinder, or a prism shape such as a square prism.

[0070] In the first embodiment, the engaging head 12 is integrally formed on the rod portion 11 via a dividing portion 13. The engaging head 12 has a relatively small vertical dimension (i.e., thickness), and when viewed from above, the engaging element 10 appears... Figure 3The device has a circular shape when viewed from above. The circular shape of the engaging head 12, which can be confirmed when viewed from above, is formed with a diameter larger than the diameter of the circle formed by the dividing portion 13 when viewed from above. In this case, when viewed from above, it is preferable that the diameter of the circular engaging head 12 is more than 110% and less than 200% of the diameter of the circle formed by the dividing portion 13.

[0071] like Figure 2 As shown, the engaging head 12 in the first embodiment has: a flat head tip surface 12a exposed upwards; a back base surface 12b extending outwards from the boundary 13 between the engaging head 12 and the rod portion 11; and an outer peripheral side surface 12c formed as a curved surface sloping downwards from the outer periphery of the head tip surface 12a to the outer periphery of the back base surface 12b. In this case, the head tip surface 12a of the engaging head 12 is arranged parallel to the upper surface of the base portion 9, and the width dimension (width dimension of the flat surface portion) of the flat head tip surface 12a in the orthogonal direction CD is equal to the width dimension (width dimension of the flat surface portion) of the portion of the rod portion 11 located at the boundary 13 in the orthogonal direction CD, or the width dimension (width dimension of the flat surface portion) of the flat head tip surface 12a in the orthogonal direction CD is greater than or equal to the width dimension (width dimension of the flat surface portion) of the portion of the rod portion 11 located at the boundary 13 in the orthogonal direction CD. Furthermore, the length dimension (length dimension of the flat surface portion) of the head tip surface 12a formed flat in the mechanical direction MD is equal to the length dimension (length dimension of the flat surface portion) of the rod portion 11 located at the dividing portion 13 in the mechanical direction MD, or the length dimension (length dimension of the flat surface portion) of the head tip surface 12a formed flat in the mechanical direction MD is greater than the length dimension (length dimension of the flat surface portion) of the rod portion 11 located at the dividing portion 13 in the mechanical direction MD. The curved outer peripheral side surface 12c is formed in the entire circumferential direction of the engaging head 12 between the head tip surface 12a and the back base end surface 12b.

[0072] The back base end face 12b of the engaging head 12 is disposed vertically on the side opposite to the top end face 12a of the head, facing the base material portion 9. Furthermore, this back base end face 12b is formed in a ring or annular shape surrounding the rod portion 11. Moreover, as... Figure 2 As shown, when viewing the engaging element 10 from the mechanical direction MD side in the front view (or rear view), the surface of the back base end face 12b along the orthogonal direction CD is formed with a back angle θ1 of 70° or more and 110° or less, preferably 70° or more and 90° or less, relative to the height direction (vertical direction) of the rod portion 11. Here, the back angle θ1 refers to the angle at which the surface of the back base end face 12b, at the end of the boundary portion 13 connecting the back base end face 12b and the rod portion 11, is inclined relative to the vertical direction.

[0073] The back angle θ1 is set to 70° or more as described above, so that the loop of the ring member, such as non-woven fabric, can easily enter the back side of the engaging head 12 and can be easily hooked. In addition, the back angle θ1 is set to 110° or less (especially 90° or less), so that when the loop of the ring member is hooked on the back side of the engaging head 12 and engaged, the engaged loop can be stably maintained, making it difficult for the loop to come off the engaging element 10.

[0074] In particular, in the case of the first embodiment, the back side angle θ1 of the back side base end face 12b is 90° (including an error of ±5%), and the back side base end face 12b of the engaging head 12 is arranged parallel to the upper surface of the base material portion 9 and the head tip surface 12a of the engaging head 12. In addition, the back side base end face 12b of the engaging head 12 is formed such that the back side angle θ1 is not only provided on the surface along the orthogonal direction CD with respect to the vertical direction, but also that the back side angle θ1 is provided with respect to the vertical direction at 90° over the entire circumference of the engaging head 12.

[0075] Furthermore, when observing the cross-section of the engaging element 10 passing through the central axis of the rod portion 11 and orthogonal to the mechanical direction MD, the back base end face 12b has a straight plane within the range from the boundary 13 between the back base end face 12b and the rod portion 11 to the boundary 13 between the back base end face 12b and the outer peripheral side surface 12c. In particular, in the first embodiment, the back base end face 12b is formed as a single flat plane over the entire circumference of the engaging head 12.

[0076] In this case, when observing the cross-section of the engaging element 10, the planar portion of the back base end face 12b is formed along the orthogonal direction CD with a length of 20 μm or more and 90 μm or less, particularly with a length of 40 μm or more and 90 μm or less. The planar portion of the back base end face 12b having a length of 20 μm or more (particularly 40 μm or more) allows the loop fastener of a typical loop member such as a disposable diaper to easily hook onto the engaging head 12 of the engaging element 10, and ensures that the hooked loop fastener is stably held on the engaging element 10. Furthermore, by having a length of 90 μm or less for the planar portion of the back base end face 12b, it is possible to prevent the engaging head 12 from becoming excessively large, thereby, for example, allowing for a stably provided space of appropriate size between adjacent engaging elements 10, depending on the forming density of the engaging elements 10.

[0077] In particular, in the case of the first embodiment, the planar portion of the back base end face 12b is formed integrally with respect to the back base end face 12b, and this planar portion has a length of 40 μm along the orthogonal direction CD. In addition, the length of the planar portion of the back base end face 12b along its radial direction of the engaging head 12 in the first embodiment is approximately the same size over the entire circumference of the engaging head 12.

[0078] Furthermore, in this invention, the back-side base end face 12b of the engaging head 12 may also be formed as a curved surface that is convexly curved along the radial direction of the engaging head 12. Alternatively, for example, the portion of the back-side base end face 12b of the engaging head 12 along the orthogonal direction CD in the radial direction of the engaging head 12 may be formed as a flat plane, while the portion along the mechanical direction MD in the radial direction of the engaging head 12 may be formed as a curved surface.

[0079] Next, the method for manufacturing the shaped surface connector 1 of the first embodiment described above will be explained.

[0080] use Figure 4 The manufacturing apparatus 20 shown is used to manufacture the molded surface connector 1 of the first embodiment. The manufacturing apparatus 20 includes: a molding device 21, which performs a one-time molding process; and a heating and pressing device 28, which heats and presses a portion of the one-time molded body 1a, which is formed by the one-time molding process and is described later.

[0081] The molding apparatus 21 of the first embodiment includes: a mold wheel 22 that is driven to rotate in one direction (counterclockwise in the figure); a nozzle portion 23 that is disposed opposite to the circumferential surface of the mold wheel 22 and causes molten synthetic resin material to flow continuously toward the mold wheel 22; and a pick-up roller 24 that is disposed downstream of the nozzle portion 23 in the rotational direction of the mold wheel 22.

[0082] The mold wheel 22 includes a cylindrical body (sleeve) 25 that serves as a mold component and a rotary drive roller 26 that rotates the cylindrical body 25 in one direction. A cooling jacket (not shown) is provided inside the rotary drive roller 26 to allow coolant to circulate, which enables efficient cooling of the one-piece molded body 1a (described later) formed from the outer peripheral surface of the mold wheel 22.

[0083] like Figure 5 As shown, a plurality of through holes 25a extending from the outer circumference of the cylindrical body 25 of the mold wheel 22 to the inner circumference are provided as a mold cavity for forming the temporary element 15 (described later) of the one-time molded body 1a. The plurality of through holes 25a are formed corresponding to the mounting positions of the engaging element 10 of the manufactured molding surface connector 1.

[0084] Furthermore, each through hole 25a has a frustum shape, where the circle formed on the outer circumferential surface of the cylindrical body 25 is larger than the circle formed on the inner circumferential surface of the cylindrical body 25. Moreover, in this invention, the material and size of the cylindrical body 25, as well as its formation method, are not particularly limited.

[0085] The picking roller 24 of the forming device 21 has a pair of rollers, namely an upper clamping roller 24a and a lower clamping roller 24b, which clamp and pull the primary forming body 1a formed from the outer peripheral surface of the mold wheel 22. The upper clamping roller 24a and the lower clamping roller 24b are arranged opposite each other at a predetermined interval.

[0086] The outer periphery of each of the upper clamping roller 24a and the lower clamping roller 24b is provided with a surface layer (not shown) formed of an elastomer such as polyurethane elastomer. This pair of rollers, the upper clamping roller 24a and the lower clamping roller 24b, rotate correspondingly in a predetermined direction at a predetermined speed, thereby enabling the one-piece molded body 1a to be smoothly fed downstream while being continuously peeled from the mold wheel 22.

[0087] The heating and pressing device 28 has a pair of rollers, an upper pressing roller (upper calendering roller) 28a and a lower pressing roller (lower calendering roller) 28b, disposed downstream of the pick-up roller 24. The upper pressing roller 28a and the lower pressing roller 28b are arranged opposite each other at a predetermined interval so as to press the temporary element 15 of the one-piece formed body 1a formed by the forming device 21 in the vertical direction, thereby reducing its height dimension (the dimension in the vertical direction) to a predetermined size. In this case, the interval between the upper pressing roller 28a and the lower pressing roller 28b can be adjusted by a height adjustment member (not shown).

[0088] The upper pressing roller 28a is used to press the upper roller 28a in order ... Figure 4 The upper pressing roller 28a is configured to rotate counterclockwise. In the first embodiment, the size of the upper pressing roller 28a is not particularly limited, and the diameter (roller diameter) of the cross section orthogonal to the rotation axis of the upper pressing roller 28a is arbitrary. Furthermore, the upper pressing roller 28a has a heating source (not shown) inside it, and its outer peripheral surface forms the portion that presses the temporary element 15 of the one-piece molded body 1a from above while heating it at a predetermined heating temperature. The lower pressing roller 28b is configured to... Figure 4 The one-piece molded body 1a is configured to rotate clockwise and is supported from below by the upper pressing roller 28a.

[0089] When manufacturing the molded surface connector 1 using the manufacturing apparatus 20 equipped with the molding device 21 and the heating and pressing device 28 as described above, a one-time molding process is first performed using the molding device 21 to form the one-time molded body 1a. In this one-time molding process, molten synthetic resin material is continuously sprayed from the nozzle 23 toward the outer peripheral surface of the rotating mold wheel 22.

[0090] In the one-step molding process of the first embodiment, the synthetic resin supplied from the nozzle section 23 to the mold wheel 22 is a thermoplastic resin having an MFR of 20g / 10min or more and 60g / 10min or less (preferably 40g / 10min or more and 60g / 10min or less) and a flexural modulus of elasticity of 1000MPa or more and 2300MPa or less (preferably 1000MPa or more and 1500MPa or less).

[0091] The MFR of the thermoplastic resin is 20g / 10min or more (preferably 40g / 10min or more), so that when the upper end of the temporary element 15 is heated and pressed to form the engaging head 12 in the secondary molding process described later, the temporary element 15 can be easily softened locally at a predetermined heating temperature and easily deformed.

[0092] As a result, the engaging element 10 can be formed by thinning the engaging head 12 of the engaging element 10 and making the back angle θ1 at the back base end face 12b of the engaging head 12 within a predetermined range. On the other hand, the MFR of the thermoplastic resin is 60 g / 10 min or less, so that when the temporary element 15 is heated and pressed in the secondary molding process, the rapid deformation of the temporary element 15 can be suppressed, and the shape of the engaging element 10 after secondary molding is stabilized.

[0093] Furthermore, the flexural modulus of the thermoplastic resin is 1000 MPa or higher, which can suppress rapid deformation of the temporary element 15 during the secondary molding process, thus stabilizing the shape of the secondary molded engaging element 10. Moreover, the rigidity of the engaging element 10 can be properly ensured, thereby preventing a decrease in the peel strength of the molded surface connector 1 due to the rigidity of the engaging element 10.

[0094] On the other hand, the flexural modulus of the thermoplastic resin is 2300 MPa or less (preferably 1500 MPa or less), which allows the temporary element 15 to be properly and quickly deformed at a predetermined heating temperature during the secondary molding process. This enables the engaging element 10 to be stably formed with a thin and flat engaging head 12 and with the aforementioned back face angle θ1 of the engaging head 12 within a predetermined range. For example, in the case of this first embodiment, polypropylene with an MFR of 40 g / 10 min and a flexural modulus of 1300 MPa can be used as the synthetic resin forming the molded surface connector 1.

[0095] In a single molding process, polypropylene with the aforementioned properties is continuously extruded from nozzle 23 in a molten state, thereby forming... Figure 6 A plurality of temporary elements 15 (sometimes referred to as temporary rods) as shown are erected on the upper surface of a one-piece molded body 1a of a base material 9. At this time, the base material 9 is formed to be longer in the mechanical direction between the nozzle 23 and the mold wheel 22. In addition, thermoplastic resin is filled into the through hole 25a of the cylindrical body 25 provided to the mold wheel 22, thereby integrally forming the frustum-shaped temporary elements 15 with the base material 9.

[0096] The one-piece molded body 1a is cooled while being supported by the outer peripheral surface of the mold wheel 22 and rotated half a turn, thereby hardening. Afterwards, the hardened one-piece molded body 1a is continuously peeled off from the outer peripheral surface of the mold wheel 22 by the pick-up roller 24. In the first embodiment, the temporary element 15 of the one-piece molded body 1a peeled off from the mold wheel 22 has a height dimension of 150 μm to 400 μm. The height dimension of the temporary element 15 refers to the vertical dimension from the upper surface of the substrate portion 9 to the top surface (upper end surface) of the circular shape of the temporary element 15.

[0097] Next, the primary molded body 1a, stripped from the mold wheel 22, is conveyed toward the heating and pressing device 28 for a secondary molding process, and is guided between the upper pressing roller 28a and the lower pressing roller 28b of the heating and pressing device 28. In this secondary molding process, at least the upper end of the temporary element 15 of the primary molded body 1a is heated by the upper pressing roller 28a, and the temporary element 15 is pressed from above to flatten the upper end of the temporary element 15.

[0098] At this time, the upper pressing roller 28a heats the temporary element 15 at a constant heating temperature that is at least 50°C lower than the melting point of the synthetic resin and at least 20°C lower than the melting point of the synthetic resin. By heating the temporary element 15 at the first temperature or higher, the upper end of the temporary element 15 can be properly and quickly flattened and deformed when pressed.

[0099] On the other hand, by heating the temporary element 15 at a temperature below the second temperature described above, excessive deformation of the temporary element 15 can be prevented, and the locking element 10 with a predetermined shape can be stably formed. For example, in the case of this first embodiment, polypropylene is used as the synthetic resin as described above, and generally, the melting point of the polypropylene is around 160°C to 170°C. Therefore, in the secondary molding process of the first embodiment, the temporary element 15 is heated by the upper pressing roller 28a at a heating temperature of 110°C or higher and 150°C or lower. For example, in the case of this first embodiment, the heating temperature of the upper pressing roller 28a is set to 140°C.

[0100] Furthermore, in this secondary forming process, the flattening amount of the temporary element 15 performed by the heating and pressing device 28 (in other words, the difference between the height of the temporary element 15 and the height of the engaging element 10) is set to be 20 μm or more and 80 μm or less. That is, the secondary forming process is performed in such a way that when comparing the height of the temporary element 15 before it is introduced into the heating and pressing device 28 with the height of the engaging element 10 relative to the base material 9 after it has been formed by the heating and pressing device 28, the height of the engaging element 10 is 20 μm or more and 80 μm or less smaller than the height of the temporary element 15.

[0101] The height dimension of the engaging element 10 refers to the vertical dimension from the upper surface of the substrate portion 9 to the flat top surface (upper end surface) of the engaging head 12. Furthermore, in this case, it is preferable that the flattening amount performed by the heating pressing device 28 is 5% or more and 40% or less of the height dimension of the temporary element 15 before pressing. By pressing the temporary element 15 with such a flattening amount, the characteristic engaging head 12 in the engaging element 10 of the first embodiment can be stably formed.

[0102] In the first embodiment, polypropylene with the predetermined MFR and flexural modulus as described above is used as the material of the molded surface connector 1, and a secondary molding process is performed under the predetermined molding conditions described above, thereby manufacturing the molded surface connector 1 of the first embodiment with the following characteristic shape: the engaging head 12 of the engaging element 10 is formed into a flat and thin shape, and the back base end face 12b is inclined at a predetermined angle relative to the vertical direction.

[0103] In the first embodiment of the molded surface connector 1 manufactured using the method described above, the back face angle θ1 of the engaging head 12 is 70° or more and 110° or less, and the back side base end face 12b has a planar portion of 20 μm or more along the radial direction of the engaging head 12. Therefore, when a ring member such as a nonwoven fabric is engaged with the first embodiment of the molded surface connector 1, the loop of the engaging head 12 hooked to the engaging element 10 is less likely to detach from the engaging element 10. Thus, the first embodiment of the molded surface connector 1 can have a high peel strength (engagement strength) relative to the ring member. Furthermore, in the first embodiment of the molded surface connector 1, the top surface of the engaging head 12 is formed flat, thus, a good skin feel can be obtained on the upper surface side of the connector on which multiple engaging elements 10 are formed.

[0104] Furthermore, in the first embodiment described above, polypropylene with an MFR of 40 g / 10 min and a flexural modulus of 1300 MPa is used as the synthetic resin for forming the molding surface connector 1. Additionally, the heating temperature of the upper pressing roller 28a in the secondary molding process is set to 140°C. However, in this invention, by varying the MFR and flexural modulus of the synthetic resin used to form the molding surface connector, and the heating temperature of the upper pressing roller 28a, within the aforementioned predetermined range, it is also possible to manufacture, for example, [the product / component / component]. Figure 7 and Figure 8 The first modified example shown has a shaped surface connector 2 for the engaging element 30, which has Figure 9 The second modified example shown has a shaped surface connector 3 for the engaging element 40.

[0105] For example, in the first variation of the first embodiment, polypropylene with an MFR of 50 g / 10 min and a flexural modulus of 1050 MPa was used as the synthetic resin for forming the molding surface connector 2. Furthermore, in the secondary molding process performed on the primary molded body, the heating temperature of the upper pressing roller 28a was set to 130°C. Therefore, the molding surface connector 2 manufactured in this first variation is connected to... Figures 1-3 Compared to the engaging element 10 of the first embodiment shown, the overall height of the engaging element 30 is smaller. In addition, in the engaging element 30 of the first modified example, the engaging head 32 is thicker than that of the first embodiment, and the diameter of the circular engaging head 32 when viewed from above is larger.

[0106] Furthermore, in the engaging element 30 of this first modified example, the back angle θ1 of the back side base end face 32b of the engaging head 32 relative to the vertical direction is set to an angle of 70° or more and 110° or less, specifically 90° (including an error of ±5%), similar to that of the engaging element 10 of the first embodiment. Additionally, the back side base end face 32b of the engaging head 32 is formed as a flat, single planar shape over the entire circumference of the engaging head 32. The planar portion of this back side base end face 32b has a length of 20 μm or more along the radial direction of the engaging head 12, specifically 50 μm.

[0107] The shaped surface connector 2 of the engaging element 30 with such a first modified example is similar to the shaped surface connector 1 of the first embodiment. It is possible to prevent the buckle hooked to the engaging head 32 of the engaging element 30 from easily detaching from the engaging element 30. Therefore, it can have a higher peel strength relative to the ring member.

[0108] In having Figure 9 In the second modified example of the locking element 40 shown, the molded surface connector 3 also uses polypropylene with an MFR of 40g / 10min or more and 60g / 10min or less, and a flexural modulus of 1000MPa or more and 1500MPa or less as its material. Furthermore, in manufacturing the molded surface connector 3 of the second modified example, the heating temperature of the upper pressing roller 28a is set to 110°C or more and 150°C or less in its secondary molding process.

[0109] Therefore, in Figure 9 In the second modified example of the engaging element 40 shown, the back angle θ1 of the back side base end face 42b of the engaging head 42 relative to the vertical direction is an angle of 70° or more and 90° or less. Furthermore, during observation... Figure 9 When the cross-section shown is parallel to the height direction of the engaging element 40 and includes the central axis portion of the rod, the planar portion of the back base end face 42b of the engaging head 42 has a length of 20 μm or more. Therefore, the shaped surface connector 3 of the engaging element 40 with the second modification example can also have a higher peel strength relative to the ring member, just like the shaped surface connector 1 of the first embodiment.

[0110] (Second Implementation)

[0111] Figure 10 This is a perspective view showing the shaped surface connector of the second embodiment. Figure 11 and Figure 12 These are the front view and top view of the engaging element in the second embodiment.

[0112] The molded surface connector 4 in the second embodiment is formed from a thermoplastic resin with an MFR of 1 g / 10 min or more and 60 g / 10 min or less, and a flexural modulus of 1600 MPa or more and 3000 MPa or less. In this case, polypropylene, polyester, nylon, polybutylene terephthalate, or copolymers thereof can be used as the thermoplastic resin. In particular, in the case of the second embodiment, the molded surface connector 4 is formed from polypropylene with an MFR of 10 g / 10 min and a flexural modulus of 2000 MPa, the MFR value of which is smaller than the lower limit of the MFR value range described in the first embodiment.

[0113] The molded surface connector 4 of the second embodiment has: a thin, flat substrate portion 9; and a plurality of engaging elements 50, which stand vertically on the upper surface of the substrate portion 9 and have a mushroom-shaped form. The substrate portion 9 is formed in the same manner as the substrate portion 9 of the molded surface connector 1 of the first embodiment.

[0114] The engaging element 50 of the second embodiment includes: a rod portion 51 that stands upright from the base material portion 9; and an engaging head 52 that is integrally formed on the rod portion 51 and is formed to extend outward from the upper end of the rod portion 51. The rod portion 51 has a frustum shape in which the area of ​​the cross section orthogonal to the vertical direction increases as it approaches the base material portion 9.

[0115] In the second embodiment, the engaging head 52 is integrally formed on the rod portion 51 by means of a dividing portion 53. This engaging head 52 is configured such that, when viewed from above, the engaging element 50 is positioned as shown in top view. Figure 12 When viewed from above, the engagement head 52 has a longer elliptical shape along the orthogonal direction CD. In this case, when viewed from above, the size of the long axis of the engagement head 52 along the orthogonal direction CD is more than 110% and less than 200% of the size of the short axis of the engagement head 52 along the mechanical direction MD, preferably more than 120% and less than 150%.

[0116] like Figure 11 As shown, the engaging head 52 of the second embodiment has: a head tip surface 52a that is exposed upward; and a back base surface 52b that extends outward from the boundary 53 between the engaging head 52 and the rod portion 51. The head tip surface 52a of the engaging head 52 is formed parallel to and flat with the upper surface of the base material portion 9.

[0117] The back base end face 52b of the engaging head 52 is disposed vertically on the side opposite to the top end face 52a of the head, facing the base material portion 9, and is formed in a ring shape surrounding the rod portion 51. Furthermore, in... Figure 11As shown, in the main view of the engaging element 50 viewed from the mechanical direction MD side, the back base end face 52b is formed with a back angle θ1 of more than 120° relative to the height direction (vertical direction) of the rod portion 51.

[0118] The forming surface connector 4 of the second embodiment described above is used in the same way as in the first embodiment described above. Figure 4 The manufacturing apparatus 20 shown, which includes a forming device 21 and a heating and pressing device 28, is used to manufacture the device. Furthermore, although the heating and pressing device 28 of the second embodiment includes a pair of rollers, an upper pressing roller 28a and a lower pressing roller 28b, the upper pressing roller 28a uses a section with a diameter (roller diameter) of 300 mm or more but less than 500 mm that is orthogonal to the rotation axis direction. Particularly in the case of the second embodiment, the upper pressing roller 28a has a diameter of 400 mm.

[0119] By using an upper pressing roller 28a with such a diameter, an elliptical engaging head 52 with the lengths of the major and minor axes in a predetermined ratio, as described above, can be easily and stably formed by the temporary element 55 of the frustum (described later). In this case, by using an upper pressing roller 28a with a larger diameter, it is possible to form an elliptical engaging head 52 in which the ratio of the size of the major axis along the orthogonal direction CD to the size of the minor axis along the mechanical direction MD becomes larger.

[0120] In the second embodiment, firstly, molding is performed using the molding device 21. Figure 13 The one-time molding process of the one-time molded body 4a shown. In this case, as the synthetic resin supplied from the nozzle 23 to the mold wheel 22, as described above, a thermoplastic polypropylene with an MFR of 10 g / 10 min and a flexural modulus of 2000 MPa is used. By using such a synthetic resin to manufacture the molded surface connector 4, the aforementioned back angle θ1 of the molded engaging head 52 becomes 120° or more, resulting in a highly rigid engaging element 50. In addition, it is easy to form the engaging head 52 into an elliptical shape when viewed from above the engaging element 50.

[0121] Furthermore, in the second embodiment, as the material for the molded surface connector 4, any thermoplastic resin with an MFR of 1 g / 10 min or more and 60 g / 10 min or less, and a flexural modulus of elasticity of 1600 MPa or more and 3000 MPa or less can be selected. Using the selected thermoplastic resin, a first molding process and a second molding process are performed as follows, thereby manufacturing the molded surface connector 4 of the second embodiment in which the engaging head 52 is elliptical when viewed from above the engaging element 50.

[0122] In the second embodiment, except for the different synthetic resin used as the material, the single-molding process is performed in the same manner as in the first embodiment described above. Thus, molding... Figure 13 A plurality of temporary elements 55, as shown, are erected on the upper surface of the substrate portion 9 in a one-piece molded body 4a. In this case, the temporary elements 55 formed in the second embodiment have the same shape as the temporary elements 15 formed in the first embodiment described above.

[0123] Next, the primary molded body 4a obtained from the primary molding process is conveyed toward the heating and pressing device 28 for the secondary molding process and is introduced between the upper pressing roller 28a and the lower pressing roller 28b of the heating and pressing device 28.

[0124] In the secondary molding process of the second embodiment, at least the upper end of the temporary element 55 of the primary molded body 4a is heated using the upper pressing roller 28a, and the temporary element 55 is pressed from above. At this time, the upper pressing roller 28a heats the temporary element 55 at a constant heating temperature, similar to that in the first embodiment, at a first temperature at least 50°C lower than the melting point of the synthetic resin and a second temperature at least 20°C lower than the melting point of the synthetic resin. For example, in this second embodiment, the heating temperature of the upper pressing roller 28a is set to 138°C. Furthermore, in this secondary molding process, the flattening amount of the temporary element 55 by the heating pressing device 28 is set to at least 20 μm and less than 80 μm.

[0125] In the second embodiment, polypropylene with the predetermined MFR and flexural modulus as described above is used as the material for the forming surface connector 4, and a secondary forming process is performed under predetermined conditions using an upper pressing roller 28a with a diameter of 300 mm or more and 500 mm or less, thereby manufacturing the forming surface connector 4 of the second embodiment in which the engaging head 52 of the engaging element 50 has the characteristic shape described above (i.e., a predetermined elliptical shape when viewed from above and a back angle θ1 of 120° or more).

[0126] In the molded surface connector 4 of the second embodiment manufactured in this manner, although the back angle θ1 of the back side base end face 52b in the engaging head 52 has an angle of more than 120°, the engaging head 52 has an elliptical shape when viewed from above the engaging element 50. Furthermore, the molded surface connector 4 is formed of polypropylene having a flexural modulus of up to 2000 MPa, which improves the stiffness of each engaging element 50. Therefore, when a ring member such as a nonwoven fabric is engaged with the molded surface connector 4 of the second embodiment, it is easy to stably maintain the engagement between the loop and the engaging element 50, and the loop hooked to the elliptical engaging head 52 of the engaging element 50 is less likely to detach from the engaging element 50.

[0127] Therefore, the shaped surface connector 4 of the second embodiment can have a higher peel strength (engagement strength) relative to the ring member. Moreover, in the shaped surface connector 4 of the second embodiment, compared with the shaped surface connector 1 of the first embodiment, the flat head tip surface 52a of the engagement head 52 is easier to be formed wider, thus making the skin feel on the upper surface side of the connector better.

[0128] Example

[0129] The present invention will be described in more detail below by way of examples.

[0130] (Example 1)

[0131] As an example 1, the conditions described in the first embodiment above were followed. Figures 1-3 The manufacturing of the molded surface connector 1 shown. Specifically, polypropylene with an MFR of 40 g / 10 min and a flexural modulus of 1300 MPa was used as the synthetic resin for forming the molded surface connector 1. In addition, the heating temperature of the upper pressing roller 28a in the secondary molding process was set to 140°C to manufacture the molded surface connector 1 of Example 1.

[0132] In the shaped surface connector 1 manufactured in this embodiment 1, the back side angle θ1 of the back side base end face 12b in the radial direction of the engaging head 12 and along the orthogonal direction CD is 90°, and the back side base end face 12b has a planar portion of 40 μm along the radial direction of the engaging head 12.

[0133] (Example 2)

[0134] As an example 2, the conditions described in the first variation of the first embodiment described above were applied. Figure 7 and Figure 8The manufacturing of the molded surface connector 2 shown. Specifically, polypropylene with an MFR of 50 g / 10 min and a flexural modulus of 1050 MPa was used as the synthetic resin for forming the molded surface connector 2. In addition, the heating temperature of the upper pressing roller 28a in the secondary molding process was set to 130°C to manufacture the molded surface connector 2 of Example 2.

[0135] In the shaped surface connector 2 manufactured in this embodiment 2, the back side angle θ1 of the back side base end face 32b in the radial direction of the engaging head 32 and along the orthogonal direction CD is 90°, and the back side base end face 32b has a planar portion of 50 μm along the radial direction of the engaging head 32.

[0136] (Comparative Example 1)

[0137] In Comparative Example 1, polypropylene with an MFR of 10 g / 10 min and a flexural modulus of 2000 MPa was used as the synthetic resin. Furthermore, the heating temperature of the upper pressing roller 28a in the secondary molding process was set to 130°C to manufacture the forming surface connector, thereby producing a... Figure 14 and Figure 15 The forming surface connector 5 of Comparative Example 1 is shown. In addition, the conditions, except for the MFR and flexural modulus of polypropylene and the heating temperature of the upper pressing roller 28a, were set in the same way as in Example 1 (First Embodiment).

[0138] The shaped surface connector 5 manufactured in Comparative Example 1 has Figure 14 and Figure 15 The multiple engaging elements 60 shown are as described. Furthermore, in this Comparative Example 1, the back face angle θ1 of the back side base end face 62b in the radial direction and along the orthogonal direction CD of the engaging head 62 is 120°. Additionally, no planar portion is formed on the back side base end face 62b of the engaging head 62 (i.e., the length of the planar portion along the radial direction in the back side base end face 62b of the engaging head 62 is 0 μm).

[0139] (Example 3)

[0140] As an example 3, the conditions described in the aforementioned second embodiment were followed. Figures 10-12 The molding surface connector 4 shown was manufactured using polypropylene with an MFR of 10 g / 10 min and a flexural modulus of 2000 MPa as the synthetic resin for forming the molding surface connector 4. Furthermore, in the secondary molding process, an upper pressing roller 28a with a diameter of 400 mm was used, and the heating temperature of this upper pressing roller 28a was set to 138°C to manufacture the molding surface connector 4 of Example 3.

[0141] In the shaped surface connector 4 manufactured in this embodiment 3, the back side angle θ1 of the back side base end face 52b in the radial direction of the engaging head 52 and along the orthogonal direction CD is 120° or more. In addition, the engaging head 52 has an elliptical shape that is longer in the orthogonal direction CD when the engaging element 50 is viewed from above, and the size of the major axis of the engaging head 52 along the orthogonal direction CD is 122% of the size of the minor axis of the engaging head 52 along the mechanical direction MD.

[0142] (Comparative Example 2)

[0143] In Comparative Example 2, the same polypropylene as in Example 3, i.e., polypropylene with an MFR of 10 g / 10 min and a flexural modulus of 2000 MPa, was used as the synthetic resin. Furthermore, in the secondary molding process, an upper pressing roller 28a with a diameter of 100 mm was used, and the heating temperature of this upper pressing roller 28a was set to 135°C to manufacture the product. Figures 16-18 The forming surface connector 6 of Comparative Example 2 is shown. In addition, in Comparative Example 2, the conditions other than the diameter of the upper pressing roller 28a and the heating temperature of the upper pressing roller 28a were set in the same way as in Example 3 (Second Embodiment).

[0144] The shaped surface connector 6 manufactured in Comparative Example 2 has Figures 16-18 The diagram shows multiple engaging elements 70. In this Comparative Example 2, the back face angle θ1 of the back side base end face 72b in the radial direction of the engaging head 72 and along the orthogonal direction CD is 120° or more. Furthermore, the engaging head 72 has a shape that is perfectly circular when viewed from above the engaging element 70, and the diameter of the engaging head 72 along the orthogonal direction CD is 98% of the diameter of the engaging head 72 along the mechanical direction MD.

[0145] After manufacturing the molded surface connectors 1, 2, 4, 5, and 6 of Examples 1 to 3 and Comparative Examples 1 and 2 respectively, the peel strength of each of the obtained molded surface connectors 1, 2, 4, 5, and 6 was measured.

[0146] In this peel strength test, such as Figure 19 As shown, the forming surface connectors 1, 2, 4, 5, and 6 of Examples 1-3 and Comparative Examples 1 and 2 were cut into dimensions of MD 25mm × CD 25mm in the mechanical direction. The cut pieces 83 of these forming surface connectors were bonded and fixed to a support member 84 made of nonwoven fabric, thereby producing a first test piece 81 on the forming surface connector side. Furthermore, a nonwoven fabric 85 with a dimension in the mechanical direction MD larger than the dimension in the mechanical direction MD of the cut piece 83 of the forming surface connector was bonded and fixed to the support member 84, thereby producing a second test piece 82 on the ring member side.

[0147] Next, as Figure 20 The cut piece 83 of the shaped surface connector in the first test piece 81 is shown engaging with the second test piece 82. Next, the first test piece 81 and the second test piece 82 are held by a pair of clamps (not shown), and then the pair of clamps holding the first test piece 81 and the second test piece 82 are moved at a constant speed toward a direction of separation, thereby gradually applying a load to the first test piece 81 and the second test piece 82 in the engaged state. The load when the engaged state is disengaged is measured, thereby determining the peel strength of the shaped surface connectors 1, 2, 4, 5, and 6.

[0148] For each of the shaped surface connectors 1, 2, 4, 5, and 6 in Examples 1-3 and Comparative Examples 1 and 2, peel strength tests were conducted on multiple shaped surface connectors, and the average value of the measured peel strength was calculated. The average value of the peel strength calculated for each shaped surface connector 1, 2, 4, 5, and 6, together with values ​​related to the manufacturing conditions of each shaped surface connector 1, 2, 4, 5, and 6 and the shape of the engaging head, are shown in Tables 1 and 2 below.

[0149] [Table 1]

[0150] MER (g / 10min) 40 50 10 Flexural modulus of elasticity (MPa) 1300 1050 2000 Heating temperature (°C) for the secondary forming process 140 130 130 Back face angle θ1 (°) 90 90 120 Length (μm) of the planar portion of the dorsal basal end face. 40 50 0 Peel strength (N / cm) 0.6 0.56 0.15

[0151] [Table 2]

[0152] MFR (g / 10min) 10 10 Flexural modulus of elasticity (MPa) 2000 2000 Heating temperature (°C) for the secondary forming process 138 135 The ratio of the major axis to the minor axis of the ellipse 1.22 0.98 Diameter (mm) of the upper pressing roller 400 100 Peel strength (N / cm) 0.53 0.09

[0153] As shown in Table 1, it is evident that the molded surface connectors 1 and 2 of Examples 1 and 2 have a peel strength that is more than 3 times that of the molded surface connector 5 of Comparative Example 1. Furthermore, as shown in Table 2, it is evident that the molded surface connector 4 of Example 3 has a peel strength that is more than 5 times that of the molded surface connector 6 of Comparative Example 2.

[0154] Furthermore, in the aforementioned first and second embodiments, the use of Figure 4 The example shown is of a forming apparatus 21 with a mold wheel 22 performing a single forming process for a forming surface connector. However, in this invention, other types of forming apparatuses may also be used in the single forming process of the forming surface connector.

[0155] For example, a forming apparatus (a so-called double-wheel or double-roller type forming apparatus) can be used as a forming apparatus for forming a one-time molded article, the forming apparatus having: a mold wheel that is driven to rotate in one direction; a pressure roller that is arranged with a predetermined interval between it and the mold wheel and is driven to rotate in the opposite direction to the mold wheel; and a nozzle that causes the molten synthetic resin to flow into the space between the mold wheel and the pressure roller.

[0156] In this case, the die wheel disposed in the double-wheel type forming device has the same characteristics as those used in the first embodiment described above. Figure 4 The mold wheel 22 shown has the same structure. By using a double-wheel type forming device with such a mold wheel and pressure wheel to perform a single forming process, it is also possible to stably manufacture the forming surface connector of the first embodiment or the second embodiment described above.

[0157] Explanation of reference numerals in the attached figures

[0158] 1. Forming surface connector; 1a. One-time formed body; 2, 3. Forming surface connector; 4. Forming surface connector; 4a. One-time formed body; 5, 6. Forming surface connector; 9. Base material part; 10. Engaging element; 11. Rod part; 12. Engaging head; 12a. Top surface of head; 12b. Back side base end face; 12c. Outer peripheral side; 13. Dividing part; 15. Temporary element; 20. Manufacturing device; 21. Forming device; 22. Die wheel; 23. Nozzle part; 24. Pick-up roller; 24a. Upper clamping roller; 24b. Lower clamping roller; 25. Cylindrical body (sleeve); 25a. Through hole; 26. Rotary drive roller; 28. Heating and pressing device; 28a. Upper pressing roller (upper calendering roller); 28b, Lower pressing roller (lower calendering roller); 30, Engaging element; 32, Engaging head; 32b, Back side base end face; 40, Engaging element; 42, Engaging head; 42b, Back side base end face; 50, Engaging element; 51, Rod; 52, Engaging head; 52a, Top surface of head; 52b, Back side base end face; 53, Dividing part; 55, Temporary element; 60, Engaging element; 62, Engaging head; 62b, Back side base end face; 70, Engaging element; 72, Engaging head; 72b, Back side base end face; 81, First test piece; 82, Second test piece; 83, Cut piece; 84, Support member; 85, Nonwoven fabric; CD, Orthogonal direction; MD, Mechanical direction; θ1, Back side angle.

Claims

1. A method of manufacturing a molded surface connector, which is a method of manufacturing a molded surface connector (1, 2, 3) made of synthetic resin, the molded surface connector (1, 2, 3) having a plurality of engaging elements (10, 30, 40) provided with a stem portion (11) rising from a base material portion (9) and an engaging head portion (12, 32, 42) integrally formed on the stem portion (11), wherein The manufacturing method includes: a primary forming step, in which a primary molded body (1a) having the substrate portion (9) and a plurality of temporary elements (15) erected on the substrate portion (9) is formed; and a secondary forming step, in which at least a portion of the temporary elements (15) of the primary molded body (1a) is heated, and the at least a portion is pressed from above, thereby forming the molded surface connectors (1, 2, 3). The manufacturing method is characterized in that... The manufacturing method includes using a thermoplastic resin with a melt flow rate of 20 g / 10 min or more and 60 g / 10 min or less, and a flexural modulus of 1000 MPa or more and 2300 MPa or less as the synthetic resin. In the secondary molding process, at least a portion of the temporary elements (15, 55) is heated at a heating temperature that is at least 50°C lower than the melting point of the synthetic resin and at least 20°C lower than the melting point of the synthetic resin, and the temporary elements (15, 55) are pressed from above to form the engaging elements (10, 30, 40, 50) whose height dimension is at least 20 μm smaller than the height dimension of the temporary elements (15, 55) and at least 80 μm smaller.

2. A manufacturing method of a molded surface connector, which is a manufacturing method of a molded surface connector (4) made of synthetic resin, the molded surface connector (4) having a plurality of engaging elements (50) provided with: a stem portion (51) that stands from a base material portion (9); a head portion (52) that is provided at a distal end of the stem portion (51); and a hook portion (53) that is provided at a distal end of the head portion (52). The engaging head (52) is integrally formed on the rod portion (51), wherein, The manufacturing method includes: a primary forming step, in which a primary molded body (4a) having the substrate portion (9) and a plurality of temporary elements (55) erected on the substrate portion (9) is formed; and a secondary forming step, in which at least a portion of the temporary elements (55) of the primary molded body (4a) is heated, and the at least a portion is pressed from above, thereby forming the molded surface connector (4). The manufacturing method is characterized in that... The manufacturing method includes: using a thermoplastic resin with a melt flow rate of 1 g / 10 min or more and 60 g / 10 min or less, and a flexural modulus of elasticity of 1600 MPa or more and 3000 MPa or less as the synthetic resin, and... In the secondary forming process, the temporary element (55) is pressed from above using a pressing roller (28a) with a diameter of 300 mm or more but less than 500 mm. In the secondary molding process, at least a portion of the temporary elements (15, 55) is heated at a heating temperature that is at least 50°C lower than the melting point of the synthetic resin and at least 20°C lower than the melting point of the synthetic resin, and the temporary elements (15, 55) are pressed from above to form the engaging elements (10, 30, 40, 50) whose height dimension is at least 20 μm smaller than the height dimension of the temporary elements (15, 55) and at least 80 μm smaller.

Images