Flexible contact fastener product

Abstract

A sheet form fastener product (10) has a flexible substrate (12), such as a lightweight nonwoven fabric, and a resin layer (14) covering only a portion of one side (16) of the flexible substrate and leaving areas (18) of the flexible substrate exposed. The resin layer (14) carries a plurality of touch fastener elements (22), each touch fastener element (22) having a resin stem (28) extending integrally from the layer (14) away from the flexible substrate (12) to an engageable head (30). A flexible ferromagnetic coating (24) is bonded to the flexible substrate (12) and extends beneath the resin layer (14) and exposed areas (18) of the flexible substrate (12). The resin layer can be arranged as spaced apart channels or islands of resin, and the coating can be arranged as spaced apart channels or islands, or otherwise leave at least a portion of the substrate exposed.

Description

[0001] Cross-reference to related applications

[0002] This application claims priority to U.S. Provisional Application No. 63 / 352,653, filed June 16, 2022, the contents of which are incorporated herein by reference in their entirety. Technical Field

[0003] This invention relates to flexible contact fastener products and methods of manufacturing and using such products. Background Technology

[0004] Vehicle seats are typically formed by molding foam padding to achieve a desired seat surface profile, and then covering the molded foam padding with upholstery or seat covers. Seat covers can be secured to the foam padding using various fasteners, such as contact fasteners. For contact fasteners, convex (hook) contact fasteners can be attached to the foam padding and are adapted to engage with fibers or loops on the underside of the seat cover. Convex contact fasteners can be fastening channels placed in the mold of the molded seat padding. Such fastening channels are often called "mold-in fasteners" and become part of the surface of the molded seat padding. One of the challenges of mold-in fasteners is that their convex contact fastener elements must remain sufficiently unobstructed during the foam molding process to expose them for engagement with the seat cover. This is particularly important for narrow fastening channels, such as fastening channels placed on narrow bases in the mold that form corresponding grooves in the seat padding.

[0005] Seat designers continue to optimize the shape and configuration of seat cushions for comfort and functionality, leading to a persistent need to improve how the cover is held to the seat cushion, especially for high-use applications where occupants must repeatedly enter and exit the vehicle. Some seat designers prefer to avoid deep creases and gathers, which are common in arches and narrow fastening passages. Beyond seat cushions, there is also a search for improvements in flexible, wide-sheet contact fasteners. Summary of the Invention

[0006] One aspect of the invention is a method for manufacturing a longitudinally continuous contact fastener product. The method includes unwinding a flexible substrate having a ferromagnetic coating, feeding the flexible substrate into a molding roll gap, and molding a resin layer on a first side of the flexible substrate, exposing a region on the first side of the flexible substrate such that the ferromagnetic coating extends beneath both the resin layer on the first side of the flexible substrate and the exposed region.

[0007] In some embodiments, when the flexible substrate is fed into the molding roll gap, the ferromagnetic coating covers only a portion of the second side of the flexible substrate.

[0008] For example, in some cases, the ferromagnetic coating is disposed in spaced apart coating channels. The coating channels can be electrically conductive along the length of the fastener product in order to conduct electrical signals or power in the finished product, or to provide resistive heating.

[0009] As another example, the ferromagnetic coating can be disposed in spaced apart coating islands, each of which is surrounded by exposed substrate.

[0010] In another example, the second side of the flexible substrate has a longitudinal selvedge that is free of ferromagnetic coating.

[0011] In some cases, the ferromagnetic coating defines a channel in which the flexible substrate is exposed. The channel can advantageously be located under a resin layer, such that the resin layer blocks flow through the channel.

[0012] In some examples, the resin layer is molded such that the contact fastener element is the only feature or only molded feature extending from the layer away from the flexible substrate.

[0013] In some embodiments, the resin layer is molded in a plurality of parallel resin channels, and the exposed area includes a plurality of locations of exposed substrate between the resin channels. In some cases, the flexible ferromagnetic coating extends under all of the parallel resin channels.

[0014] In some embodiments, the resin layer is molded in a plurality of resin islands, each of which is surrounded by the exposed area.

[0015] In some cases, feeding the flexible substrate into the molding nip involves feeding a nonwoven textile material into the molding nip.

[0016] In some examples, the flexible ferromagnetic coating is impermeable to air, e.g., at low pressures or pressures encountered in use.

[0017] The flexible ferromagnetic coating can include iron-containing particles, e.g., stainless steel particles, suspended in a polymeric material.

[0018] The method can further include, after molding the resin layer, winding the contact fastener product to form a roll.

[0019] The flexible substrate can have a width, e.g., between 5 and 60 centimeters, when fed into the nip.

[0020] Another aspect of the invention features a fastener product having a flexible substrate, a resin layer covering only a portion of a first side of the flexible substrate and exposing an area of the first side of the flexible substrate, and a flexible ferromagnetic coating bonded to the flexible substrate. The resin layer carries a plurality of contact fastener elements, each having a resin stem integrally extending from the layer away from the flexible substrate to an engageable head. The flexible ferromagnetic coating is bonded to the flexible substrate on a second side of the flexible substrate and extends under the resin layer and exposed area of the first side of the flexible substrate, leaving at least a portion of the second side of the flexible substrate exposed and free of ferromagnetic coating.

[0021] In some embodiments, the ferromagnetic coating is arranged in spaced-apart coating pathways. The coating pathways can be electrically conductive along the length of the fastener product, in order to conduct electrical signals or power in the final product, or to provide resistive heating.

[0022] In some embodiments, the ferromagnetic coating is arranged in spaced-apart coating islands, each surrounded by exposed substrate.

[0023] In some cases, the second side of the flexible substrate has a longitudinal selvedge that is free of ferromagnetic coating.

[0024] The ferromagnetic coating can define a channel in which the flexible substrate is exposed. Such a channel can advantageously be located under the resin layer, such that the resin layer blocks flow through the channel, e.g., of foamed resin.

[0025] In some examples, the contact fastener elements are the only features extending from the layer away from the flexible substrate or the only features of the molded resin.

[0026] In some embodiments, the layer includes a plurality of parallel resin pathways, and the exposed area includes a plurality of locations of exposed substrate between the resin pathways. In some cases, the flexible ferromagnetic coating extends under all of the parallel resin pathways. The ferromagnetic coating can be arranged in spaced-apart coating pathways. The coating pathways and resin pathways can advantageously not significantly overlap in thickness, e.g., to improve stability and density when wound on a roll.

[0027] In some embodiments, the resin layer includes a plurality of resin islands, each surrounded by the exposed area.

[0028] In some examples, the flexible substrate includes or consists of a nonwoven textile material.

[0029] In some cases, the flexible ferromagnetic coating is gas impermeable.

[0030] The flexible ferromagnetic coating can include iron-containing particles, e.g., stainless steel particles, suspended in a polymeric material.

[0031] In some examples, the fastener product is wound on a roll. In some cases, the flexible substrate has a selvedge on a side opposite the contact fastener elements, the flexible substrate being exposed in the selvedge. The flexible ferromagnetic coating can cover the entire side opposite the contact fastener except for the selvedge.

[0032] In some examples, the fastener product has a width between 5 cm and 60 cm.

[0033] According to another aspect of the invention, a fastener product includes a flexible substrate, a resin layer covering only a portion of a first side of the flexible substrate and leaving an area of the first side of the flexible substrate exposed, and a flexible ferromagnetic coating bonded to the flexible substrate on a second side of the flexible substrate and extending under the resin layer and exposed area of the first side of the flexible substrate. The resin layer carries a plurality of contact fastener elements, each having a resin stem integrally extending from the resin layer away from the flexible substrate to an engageable head. The resin layer itself includes or is in the form of a plurality of resin islands, each surrounded by the exposed area of the flexible substrate.

[0034] In some embodiments, the ferromagnetic coating covers only a portion of the second side of the flexible substrate.

[0035] For example, in some configurations, the ferromagnetic coating is arranged in spaced-apart coating pathways. The coating pathways can be electrically conductive along the length of the fastener product.

[0036] In some cases, the ferromagnetic coating is arranged in spaced-apart coating islands, each surrounded by the exposed substrate.

[0037] In some cases, the second side of the flexible substrate has a longitudinal selvedge that is free of the ferromagnetic coating.

[0038] In some embodiments, the ferromagnetic coating defines channels in which the flexible substrate is exposed. These channels can be located under the resin islands, such that the resin layer blocks flow through the channels, e.g., of foamed resin.

[0039] In some examples, the contact fastener elements are the only features extending from the resin islands away from the flexible substrate, or are the only features integrally molded with the resin islands and extending from the resin islands away from the flexible substrate.

[0040] In some cases, the flexible substrate is, includes, or consists of a nonwoven textile material.

[0041] In some cases, the flexible ferromagnetic coating is gas impermeable.

[0042] The flexible ferromagnetic coating can include iron-containing particles, e.g., stainless steel particles, suspended in a polymeric material.

[0043] In some examples, the fastener product is wound on a roll. In some cases, the flexible substrate has a selvedge on the side opposite the contact fastener elements in which the flexible substrate is exposed. The flexible ferromagnetic coating can cover the entire side opposite the contact fastener except for the selvedge.

[0044] In some examples, the fastener product has a width between 5 cm and 60 cm.

[0045] Various embodiments of the invention can be used to provide fastening functionality for seat covers on discrete but relatively wide areas of seat padding to help prevent the seat cover from wrinkling across the fastened areas in use and to provide a conforming engagement of the seat cover across, for example, a wide concave seat surface. Various embodiments enable the use of particularly inexpensive materials and can be readily configured for various applications.

[0046] The details of one or more embodiments of the application are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the application will be apparent from the description and drawings, and from the claims. BRIEF DESCRIPTION OF DRAWINGS

[0047] Figure 1 is a perspective view of a first flexible fastener product.

[0048] Figure 2 is an end view of the fastener product of Figure 1

[0049] Figure 3 is a magnified side view of one of the contact fastener elements of the product of Figure 1

[0050] Figures 4-7 is an end view of other flexible fastener products having different ferromagnetic coating arrangements.

[0051] Figure 8 is a magnified view of a portion of the product of Figure 4

[0052] Figure 9 is a perspective view of a flexible fastener product having a coating-free selvedge.

[0053] Figure 10 is a perspective view of a flexible fastener product having a resin layer composed of spaced-apart islands.

[0054] Figure 10A is a perspective view of a flexible fastener product having a resin layer composed of spaced-apart channels and a ferromagnetic coating composed of spaced-apart islands. ​​​

[0055] Figure 11 is an enlarged cross-sectional view through the thick ferromagnetic coating and substrate.

[0056] Figure 12 is a schematic view of a method and apparatus for manufacturing a continuous flexible touch fastener product.

[0057] Figure 13 is a perspective view of a seat cushion including Figure 1 a touch fastener product.

[0058] Figure 14 illustrates in cross-sectional view a touch fastener product of Figure 1 installed in a seat cushion mold.

[0059] Figure 15 is a cross-sectional view of a portion of a seat cushion formed with Figure 1 a touch fastener product having a recess or channel within the product.

[0060] Like reference numbers in the various drawings indicate like elements. DETAILED DESCRIPTION

[0061] Referring first to Figure 1 , the fastener product 10 in the form of a sheet has a flexible substrate 12 with a resin layer 14 covering only a portion of one side 16 of the flexible substrate, leaving one or more areas 18 of the side of the flexible substrate exposed. In the product 10, the resin layer 14 is in the form of a plurality of parallel channels 20 of resin separated by exposed substrate areas 18 between the channels. Each channel 20 of the resin layer 14 carries a plurality of touch fastener elements 22 exposed and configured to hook fibers to form releasable touch fastening. The exposed substrate areas 18 between the channels are free of any touch fastener elements. As will be discussed further below, a flexible ferromagnetic coating 24 is bonded to the flexible substrate (in this example, on the surface of the substrate opposite the side having the resin layer and touch fastener elements) and extends under the resin layer 14 and exposed areas 18 of the flexible substrate. In this example, the coating 24 covers substantially the entire opposite surface of the substrate. In many examples, as described below, the coating 24 leaves at least a portion of the opposite surface of the substrate exposed. As a sheet product, the fastener product 10 can be said to define a plane when flat and is flexible so as to readily bend out of its plane in any direction, for example following a surface of compound curvature. While in this example the exposed upper surface of each channel 20 is flat, in another configuration (not shown) each channel has a reinforcing rib extending along each longitudinal edge and from the resin layer 14 to a height no greater than the height of the touch fastener elements to increase the bending stiffness of the product about the transverse machine axis.

[0062] Also with reference to Figure 2 and Figure 3 , the flexible substrate 12 is or includes a nonwoven fabric to which both the resin layer 14 and the ferromagnetic coating 24 are permanently affixed. The resin layer 14 is preferably molded directly onto the substrate such that the resin of the resin layer 14 encapsulates the individual fibers of the substrate surface during molding and then cures to hold the layer in close engagement to the substrate surface. The bond between the fabric and the resin should be strong enough to withstand the separation forces caused by the hooked fibers disengaging from the contact fastener elements. In Figure 2 , the contact fastener elements 22 are shown as having flat vertical sides due to their being continuously molded, the resin forming the base 26 of the resin layer passageway in a cavity defined between concentrically stacked plates of a molding roll during the continuous molding process, as described below with reference to Figure 12 . Figure 3 A side view of a single contact fastener element 22 is shown, showing the general profile of the cavity in which the contact fastener element is molded. Each contact fastener element 22 has a resin stem 28 that integrally extends from the layer 14 away from the flexible substrate 12 to an engageable head 30. In this example, the contact fastener element 22 is shown as a J-shaped hook having a single head 30 that points along the length of the resin layer passageway that carries the contact fastener element 22, which length corresponds to the machine direction of the continuous manufacturing process that forms the contact fastener element 22. In other examples, the contact fastener elements are other types known in the art, such as palm tree or mushroom types. As shown in this example, the flexible ferromagnetic coating 24 that is bonded to the flexible substrate 12 extends under all of the passageways 20 of the resin layer 14 and all of the exposed areas 18 on the opposite side of the flexible substrate 12, and the contact fastener elements 22 are the only features that extend from the layer 14 away from the flexible substrate 12, the layer having a generally constant resin thickness with a flat upper surface.

[0063] For molded-in applications, the flexible ferromagnetic coating 24 preferably provides a barrier to or blocks the flowing foam during formation of the associated seat cushion. For some applications, the flexible ferromagnetic coating 24 is completely air impermeable. In some cases, the coating is sufficiently permeable to allow trapped air to escape under the molding pressure. While the coating itself is flexible, it does add some stiffness to the substrate. This can allow the use of an even lighter, more flexible (and possibly less expensive) substrate material.

[0064] Figures 4-7 Different configurations of the flexible ferromagnetic coating 24 are shown. In each configuration, the coating is on a nonwoven fabric substrate 12 that has resin passageways carrying contact fastener elements 22, as in the example of Figure 1 .

[0065] exist Figure 4 In this configuration, a flexible ferromagnetic coating 24 is arranged in coating channels 32, with the exposed substrate visible between the coating channels. Across the width of the product (i.e., perpendicular to the resin and coating channels), each coating channel 32 overlaps the edges of two adjacent resin channels 20, such that the coating provides a barrier against foam intrusion through the exposed area 18 between the channels of the resin layer 14. In this way, it can be said that the coating extends beneath both the exposed area 18 and the resin layer 14. In some cases, the overlap is smaller, such that the coating is not directly positioned beneath any contact fastener element. The area of ​​the substrate 12 between the coating channels 24 can be said to be exposed through channels 34 defined by the flexible ferromagnetic coating 24. In this example, the channel 34 is located beneath the resin layer 14, such that the resin layer 14 prevents flow through the channel 34, while the coating channels prevent flow through the area 18 of the substrate exposed on the opposite side of the product.

[0066] Because the coating pathways are separated from each other, the coating is discontinuous across the width of the product, so the coating itself does not significantly reduce the product's ability to bend to conform to the surface of a bending die. Instead, the combination of the hardening effects of the alternating resin layer pathways and coating pathways provides approximately consistent flexural stiffness across the width of the product, where the resin layer pathways help prevent wrinkling and coalescence of the substrate between the coating pathways, and vice versa. Furthermore, for example, where the ferromagnetic coating contains sufficient iron content to transmit electrical signals, the separated coating pathways can act as parallel conductors for transmitting signals along the product, and possibly for transmitting electricity. For example, in car seats, this conductivity can be used for occupant sensing or padding heating. Similarly, the entire width of the coating can be grounded and used for radiation shielding and electrostatic dissipation functions.

[0067] Figure 5 The configuration is similar to Figure 4 The configuration differs in that the coating passages 32 are positioned on the same side of the substrate 12 as the resin passages 20, with each coating passage 32 positioned between and parallel to two adjacent resin passages 20. The coating passages may be adjacent to the longitudinal edges of the resin passages, or may be spaced apart from the resin passages by a narrow region of the exposed substrate, as shown. In this example, the opposite side or back side of the product is the substrate exposed across its entire width. In this configuration, the thickness of the resin and coating is not cumulative, allowing the product to be wound even more tightly in some cases without increasing the curvature of the substrate. For molding applications, any narrow region 18 of the exposed substrate between the coating passages and the resin passages should be narrow enough to impede the flow of the foamed resin and to prevent complete blockage of contact fastener elements.

[0068] Figure 6 configuration and Figure 4The difference in configuration is that the coating passage 32 does not overlap with the resin passage 20 in the width direction. However, the coating passage does lie below at least most of the exposed area 18 between the resin passages. In some cases, the longitudinal edge of the coating passage is vertically aligned with the longitudinal edge of the resin passage.

[0069] Figure 7 The configuration is characterized by a flexible ferromagnetic coating 24 extending on the same side of the substrate 12 as the resin passages 20 and below all resin passages to form a foam intrusion barrier and a magnetic attraction layer on the side of the product facing the liner mold surface. For this configuration, the coating itself preferably comprises ferromagnetic particles suspended in a resin matrix, which compatibly bonds with the resin of the resin layer when the resin layer is molded onto the coating.

[0070] Now for reference Figure 8 When fastener products have such Figure 4 In the configuration shown, or in any other configuration where the flexible ferromagnetic coating is present in the area between the resin channels, the attraction between the coating and the magnet 36 embedded in the mold wall 38 causes the thin, flexible substrate 12 to bend toward the mold wall, while at the resin channels, the contact fastener element 22 keeps the substrate slightly spaced from the mold surface. The effect is magnified in this figure for illustration. Depending on the spacing between the resin channels, the flexibility of the substrate, and the strength of the magnetic attraction, the substrate can be positioned directly on the mold surface between the hook channels during foaming. This may be particularly desirable along the edges of the product to help suppress foam intrusion around the edge fastener element. It should be noted that in these examples, the product does not have any added foam barrier features to prevent foam intrusion, whether as a gasket or as a molding feature of the product. Instead, these products are designed to accommodate limited foam intrusion around the edges, thus exposing sufficient contact fastener elements to engage with the seat cover. This can be a particular advantage of configuring the product relatively wide, for example, between 5 cm and 60 cm in width, and even longer in length, such that edge foam intrusion that would block even all two external resin channels will leave enough exposed hooks in the internal channels to hold the seat cover in place.

[0071] Now for reference Figure 9 Another fastener product and Figure 1 The only difference with product 10 is that the flexible ferromagnetic coating 24 does not extend across the entire back side of the product. Instead, the uncoated selvage 40 extends along the longitudinal edge of the product, with the base 12 exposed on the back side. The uncoated selvage can help enhance the product's anchoring into the foam because it does not remain tightly against the mold surface during liner formation. The lack of ferromagnetic coating in the selvage allows it to shift away from the mold surface through the flowing and expanding foam, thus becoming more deeply embedded in the foam.

[0072] Figure 10 Another example of a fastener product sheet is shown, which is similar to the fastener product sheet of Figure 1 but with the resin layer 14 configured as a plurality of islands 42 of resin, each island surrounded by an exposed area of the substrate 12. Each island 42 carries a plurality of contact fastener elements 22 as described above. Because the resin layer is discontinuous in all directions across the product, the resin layer itself does not appreciably increase the stiffness of the product in any direction. Rather, the flexible ferromagnetic coating 24 serves to add the required stiffness to the inexpensive nonwoven substrate. The islands 42 can be uniformly spaced in a regular grid pattern, or can be arranged in a non-uniform pattern according to the desired distribution of fastening properties in the final product for its intended application. Further, the islands can each have any desired perimeter shape. As with the fastener product described above, the islands themselves have no features extending upward from their flat upper surface other than the contact fastener elements, and have no specific foam barrier around their perimeters.

[0073] Figure 10A Another example of a fastener product sheet is shown, which is similar to the fastener product sheet of Figure 1 but with the ferromagnetic coating 24 configured as a pattern of spaced-apart coating islands 43 on the non-fastening side of the product sheet. The coating islands are spaced apart such that the substrate 12 is exposed between adjacent islands, and each island is elongated in the cross-machine direction to span two adjacent channels 14 of the resin layer on the fastening side of the product sheet. The coating islands can be applied by, for example, gravure printing or inkjet printing. The spanning of the coating islands across the space between adjacent resin layer channels helps to avoid buckling or wrinkling of the substrate between the resin layer channels, facilitating proper placement in the mold and allowing the use of even thinner, more flexible substrates. The spacing of the coating islands also helps to reduce the amount of coating material employed in the product sheet, thereby reducing material costs. Other arrangements of the coating island pattern and shape are contemplated in addition to the example shown.

[0074] Reference is next made to Figure 11, the flexible ferromagnetic coating 24 coats one side of the substrate 12, in many cases forming a backing with a smooth exposed surface 46 that is free of substrate fibers. In other examples, the coating coats individual fibers of the substrate surface, but is not of sufficient thickness to provide a smooth backing. Rather, the coated surface retains the rough topography caused by the distribution of the substrate fibers. In either case, the coating preferably encapsulates at least a portion of the outermost fibers of the substrate. The coating is applied as a flowable material, with discrete magnetically attractable particles 44 suspended in the flowable material. After application, the material cures or stabilizes to form a permanent but flexible coating that contains the particles 44. An example of a suitable ferromagnetic material that can be sprayed or screen printed onto a fabric is a 50 / 50 weight mixture of 45 micron stainless steel powder (product code 430L, available from Advantage Metal Powders, Richwood, PA, USA) and water-based acrylic paint ES 7174 gray (from Prisa Paint, Mexico). In arrangements such as Figure 7 In arrangements such as

[0075] Referring to Figure 12 , a method and apparatus for continuously forming Figure 1 the product 10 features first molding the resin layer and its fastener elements directly on the surface of a web of fabric, as taught in U.S. Patent No. 6,248,419 to Kennedy et al., in discrete islands or spaced-apart pathways, as taught in U.S. Patent No. 7,048,818 to Krantz et al., the contents of both patents regarding the forming method and the pathway / island distribution and substrate material being incorporated herein by reference. The forming method includes introducing a flowable resin with a preformed nonwoven substrate 12 into a nip between a rotating molding roll 48 and a pressure roll 50. In the molding nip, the resin encapsulates the surface fibers of the substrate and also fills individual blind cavities in the molding roll to form at least the stems of the fastener elements. The resin can be introduced as a continuous pathway of resin, for example from a deckled die as shown, to form a resin fastener pathway on the web (e.g., Figure 1resin can be introduced as a discrete deposit of resin, for example by printing such a deposit onto the surface of the molding roll or fabric sheet immediately upstream of the molding nip between rolls 48 and 50. Once the substrate and resin have been carried on the cooled molding roll for sufficient time to cure the resin, the substrate is stripped from the roll by passing over stripping roll 52. If only the fastener element stem is molded on roll 48, the head can be formed on the stem at this point, for example to form a mushroom-type fastener element as is known in the art. At this point, preformed product 54 is a dimensionally stable fastener material having resin passages or islands on one side, each carrying an engageable fastener element. Such a product can be wound for later processing, or fed directly into a ferromagnetic coating application station 56 as shown.

[0076] In station 56, a flowable ferromagnetic coating material is applied to preformed material 54, for example by using a transfer roll 58 to transfer the coating material directly to the backside of the preformed material, or using a sprayer 60 to spray the coating onto the substrate. If the coating is applied only in the passages, the coating can be sprayed through a stencil, or rolled on using a narrow transfer roll on the backside of the preformed product or on the fastening side of the preformed product between the resin passages. In this case, optical sensors or known web alignment techniques can be employed to ensure that the coating passages are properly positioned relative to the resin passages. After the coating material is applied, the coating can be stabilized by drying or curing, for example by passing under a UV light through an oven, and fastener product 10 can then be collected as a spool 62 for storage or transport.

[0077] However, in many cases, Figure 12 The molding process shown in FIG. 6 would begin with a spool of substrate having a coating already applied. This coated substrate is fed into the nip to form a resin layer as passages or islands, and the resulting product is then wound. This method eliminates the need to apply the coating in-line with the resin molding process. The coating can be pre-applied as passages, with the substrate aligned as it enters the molding nip to ensure that any resin passages are properly positioned relative to the coating passages. In this sense, Figure 12 A method of manufacturing a longitudinally continuous touch fastener product 10 is shown by: unwinding a flexible substrate 12 having a pre-applied ferromagnetic coating; feeding the flexible substrate into a molding nip (i.e., the nip between rolls 48 and 50); and molding a resin layer on one side of the flexible substrate, leaving regions of the one side of the flexible substrate exposed, such that the ferromagnetic coating extends under both the resin layer and the exposed regions of the one side of the flexible substrate (such as in product 10 of FIG. 1). Figure 1

[0078] ​For products to be separated into discrete sections for use, the nip between rollers 58 and 64 can also be used as a die cutting nip, where the product is at least partially cut around the outer periphery of the section to be separated from the wound product for installation.

[0079] Referring next to Figure 13 One application of the fastener product described herein is the manufacture of a foam seat cushion to be covered by a trim cover. In this example, the cushion 66 is formed from molded foam and is molded to define a wide, elongated recess or channel 68. The location and size of this recess is merely representative to illustrate the function of the fastener product; in a commercial seat cushion, the location and shape of various recesses will be determined by the seat designer to provide the desired appearance, comfort, and functionality of the covered cushion. Figure 1 The fastener product 10 is permanently attached to the foam to form the surface of the channel 68, with the resin passages 20 extending along the channel and the base 12 exposed between the passages. The fastener product has been molded into the foam by the in-mold process described below. In many cases, the edges of the product will be embedded in the foam, further helping to anchor the fastener product in the foam. Notably, the fastener product provides multiple channels of exposed fastener elements for engagement with a seat cover, and these passages follow the desired profile of the channel, with the fastener elements extending generally perpendicular to the local channel surface. In this way, the fastener product 10 forms a generally concave fastening site that follows the compound curvature of the channel, even when the channel extends around the edge of the cushion to form an aligned recess on both the top and front of the cushion. For use in lining a wide recess such as channel 68, the fastener product 10 can be provided on a spool of the desired width, so that the operator need only cut a length of product from the spool and place it into a mold to form the cushion. An example of such a product and spool width is 60 millimeters, but in various applications the product width is between 50 millimeters and 600 millimeters. Such a 60 mm wide product can be slit from a manufacturing width of, for example, 30 centimeters, before being wound.

[0080] Referring next to Figure 14A foam seat cushion can be formed in a mold cavity 70 defined between two mold halves 72 (only one of which is shown). Prior to introducing liquid foaming resin into the cavity, a molded-in product (e.g., product 10) is placed against the surface of the mold halves 72 and held in place by the attractive force between a series of permanent magnets 36 embedded in the surface of the mold and the ferromagnetic coating 24 of the molded-in product. Magnets 36 can be positioned to align with the coating pathways if the coating is arranged in pathways, or otherwise to hold the entire perimeter of the molded-in product 10 against the surface of the mold to prevent foaming resin from invading the fastening sites of the molded-in product and blocking the fastening elements. Magnets 36 not only hold the product against the surface of the mold, but can also help to position the product precisely on the surface. With the molded-in product positioned, the mold cavity is closed and the expanding foaming resin is bonded to the exposed back surface of the molded-in product. When the cured foam seat cushion is pulled from the mold, the molded-in product 10 is embedded in its surface, and the fastener elements are exposed for engagement with the underside of a seat cover, as shown in Figure 15

[0081] In the above-described example of a fastener product, the substrate 12 is a polypropylene SMS type nonwoven material having a basis weight of 106 grams per square meter, available from Sommers Nonwoven Solutions of Mooresville, North Carolina, USA. Other examples of nonwoven fabric substrates include other SMS nonwovens, such as polypropylene having a weight range of 30 to 200 gsm (preferably 100 to 150 gsm), and spunbond nonwovens, such as Foamguard LX 47754 and LX Grey FR 15025, both available from Hanes Companies (https: / / hanescompanies.com / ), Leggett & Platt company. However, other types of substrates can be employed, such as lightweight knits or even suitable films.

[0082] While a number of examples have been described for purposes of illustration, the foregoing description is not intended to limit the scope of the present application, which is defined by the scope of the appended claims. Other examples and modifications within the scope of the claims will occur to those of ordinary skill in the art.​

Claims

1. A method for manufacturing a longitudinally continuous contact fastener product (10), the method comprising: Unwinding a flexible substrate (12) with a ferromagnetic coating (24); The flexible substrate is fed into the molding roller gap; as well as A resin layer (14) is molded on a first side of the flexible substrate, exposing a region (18) on the first side of the flexible substrate, such that the ferromagnetic coating (24) extends beneath both the resin layer (14) and the exposed region (18) on the first side of the flexible substrate.

2. The method according to claim 1, wherein, When the flexible substrate (12) is fed into the molding roll gap, the ferromagnetic coating (24) covers only a portion of the second side of the flexible substrate (12).

3. The method according to claim 2, wherein, The ferromagnetic coating (24) is arranged in spaced-apart coating passages, particularly wherein the coating passages (32) are conductive along the length of the fastener product, or wherein the ferromagnetic coating (24) is arranged in spaced-apart coating islands (43), each coating island being surrounded by an exposed substrate.

4. The method according to claim 2, wherein, The second side of the flexible substrate (12) has a longitudinal woven edge (40) without a ferromagnetic coating, and / or wherein the ferromagnetic coating (24) defines a channel (34) in which the flexible substrate (12) is exposed, particularly wherein the channel (34) is located below the resin layer (14) such that the resin layer prevents foam from flowing through the channel.

5. The method according to any one of the preceding claims, wherein, The resin layer (14) is molded such that the contact fastener element (22) is the only feature extending from the resin layer (14) away from the flexible substrate (12), and / or wherein, Feeding the flexible substrate into the molding roll gap includes feeding a nonwoven textile material into the molding roll gap, and / or wherein the flexible ferromagnetic coating (24) is airtight.

6. The method according to any one of claims 1 to 4, wherein, The resin layer (14) is molded in a plurality of parallel resin channels (20), and wherein the exposed regions (18) include a plurality of sites of exposed substrate between the resin channels, and in particular wherein the flexible ferromagnetic coating (24) extends beneath all the parallel resin channels (20).

7. The method according to any one of claims 1 to 4, wherein, The resin layer (14) is molded in a plurality of resin islands, each resin island being surrounded by the exposed region (18).

8. The method according to any one of claims 1 to 4, wherein, The flexible ferromagnetic coating (24) comprises iron-containing particles (44) suspended in a polymer material, particularly wherein the iron-containing particles (44) comprise stainless steel particles.

9. A fastener product (10), comprising: Flexible substrate (12); A resin layer (14) that covers only a portion of the first side (16) of the flexible substrate and exposes a region (18) of the first side of the flexible substrate, the resin layer (14) carrying a plurality of contact fastener elements (22), each contact fastener element (22) having a resin rod (28) integrally extending from the resin layer (14) away from the flexible substrate (12) to an engageable head (30). as well as A flexible ferromagnetic coating (24) is bonded to the flexible substrate (12) on the second side of the flexible substrate and extends beneath both the resin layer (14) and the exposed region (18) on the first side (16) of the flexible substrate (12), such that at least a portion of the second side of the flexible substrate is exposed and without the ferromagnetic coating.

10. The fastener product according to claim 9, wherein, The ferromagnetic coating (24) is arranged in spaced-apart coating passages, particularly wherein the coating passages (32) are conductive along the length of the fastener product, or wherein the ferromagnetic coating (24) is arranged in spaced-apart coating islands (43), each coating island being surrounded by an exposed substrate.

11. The fastener product according to claim 9 or 10, wherein, The second side of the flexible substrate (12) has a longitudinal selvage (40) without a ferromagnetic coating, wherein the flexible substrate (12) is exposed in the longitudinal selvage, and wherein the flexible ferromagnetic coating (24) covers the entire side opposite the contact fastener except for the selvage (40).

12. The fastener product according to claim 9 or 10, wherein, The contact fastener element (22) is the only feature that extends from the resin layer (14) away from the flexible substrate (12), and / or wherein the flexible substrate (12) comprises a nonwoven textile material, and / or wherein the flexible ferromagnetic coating is airtight.

13. The fastener product according to claim 9 or 10, wherein, The resin layer (14) includes a plurality of parallel resin channels (20), and wherein the exposed area (18) includes a plurality of exposed substrate portions between the resin channels, particularly wherein the flexible ferromagnetic coating (24) extends beneath all the parallel resin channels (20), and / or wherein the ferromagnetic coating (24) is arranged in spaced-apart coating channels, and the coating channels (32) and the resin channels (20) do not overlap in thickness.

14. The fastener product according to claim 9 or 10, wherein, The resin layer (14) includes a plurality of resin islands, each of which is surrounded by the exposed region (18).

15. The fastener product according to claim 9 or 10, wherein, The ferromagnetic coating (24) defines a channel (34) in which the flexible substrate (12) is exposed, particularly wherein the channel (34) is located below the resin layer (14) such that the resin layer prevents foam from flowing through the channel, and / or wherein the flexible ferromagnetic coating (24) comprises iron-containing particles (44) suspended in a polymer material, particularly wherein the iron-containing particles (44) comprise stainless steel particles.

Images