Sheet with male molded hook-and-loop fastener that is excellent in quietness and its manufacturing method

Abstract

In this male mold hook-and-loop fastener-equipped sheet, a non-foamed resin sheet (B) is integrated with the reverse of a male mold hook-and-loop fastener (A). The male mold hook-and-loop fastener (A) comprises: a resin-made substrate (a1); and a plurality of male engagement elements (a2) that rise up from the obverse of the substrate (a1) and that are aligned in columns on the substrate (a1). The male engagement elements (a2) are bent midway along the male engagement elements in the same direction as the column direction of the male engagement elements and the leading end parts thereof approach the substrate (a1). Further, the male engagement elements (a2) are formed from the same resin as the resin that constitutes the substrate (a1). The non-foamed resin sheet (B) is directly stacked on and integrated with the reverse of the male mold hook-and-loop fastener (A). The resin that constitutes the non-foamed resin sheet (B) contains, as a main component, an elastomer resin in the same lineage as the resin that constitutes the male mold hook-and-loop fastener (A). The resin that constitutes the non-foamed resin sheet (B) is configured to have a lower hardness than the resin that constitutes the male mold hook-and-loop fastener (A).

Description

[Technical Field]

[0001] The present invention relates to a sheet with a male molded surface fastener that is quiet and emits little noise when disengaging from a surface fastener having loop-shaped engaging elements, and to a method for producing the same. [Background technology]

[0002] Conventionally, one of the means for attaching an object to the surface of an object is to attach a male hook-type or mushroom-type hook-and-loop fastener to one surface of the object and a female hook-and-loop fastener to the other surface of the object, and then overlap the hook-and-loop fastener surfaces to engage both hook-and-loop fasteners, thereby fixing the object to the surface of the object.

[0003] The advantage of such hook-and-loop fasteners is that they can be repeatedly engaged and released, and even after repeated engagement and release, they maintain a high engagement force. On the other hand, the disadvantage of hook-and-loop fasteners is that they make a loud crackling noise when released, making them unsuitable for applications where engagement and release of hook-and-loop fasteners is required in quiet environments.

[0004] For example, when hook-and-loop fasteners are used on infant products, the sound they make when they are removed can disturb the infant's sleep. Furthermore, when hook-and-loop fasteners are used on military equipment, clothing, shoes, helmets, and other items, the sound they make when they are removed can lead to the enemy's detection. Furthermore, when hook-and-loop fasteners are removed from hook-and-loop fastener-equipped items in quiet locations, such as bird watching or listening to music, the sound they make can cause birds to fly away or disturb audience members who are deeply engrossed in the music. Furthermore, when hook-and-loop fasteners are used on golf gloves, the sound they make when they are removed can disrupt the concentration of other players. Furthermore, the crackling sound they make when they are removed is far from being a luxurious sound. Regardless of the application for which hook-and-loop fasteners are used, it is preferable that the sound they make when they are removed be as quiet as possible. For these reasons, there is a demand for hook-and-loop fasteners that make less noise when they are removed.

[0005] It is said that the male hook-and-loop fastener is the main cause of the loud peeling noise that occurs when a hook-and-loop fastener is peeled off, and in response to the above-mentioned requirements, there is a demand for a male hook-and-loop fastener that produces less peeling noise, so-called quiet male hook-and-loop fasteners, and several proposals have been made to meet this demand. For example, Patent Document 1 describes that a male hook-and-loop fastener with vibration-damping material has excellent quietness, and is made by attaching a vibration-damping layer made of natural or synthetic rubber to the back side of a textile hook-and-loop fastener having a large number of male engaging elements made of monofilaments with a fineness of 100 to 500 decitex on the surface of a woven or knitted base fabric.

[0006] Patent Document 2 also describes a woven male or female hook-and-loop fastener in which peeling noise is reduced by laminating an adhesive layer on the back surface of the woven fabric hook-and-loop fastener, which has on the surface of a woven base fabric a large number of hook-shaped engaging elements made of monofilaments with a thread diameter of 0.1 to 0.3 mm or loop-shaped engaging elements made of multifilament threads of 100 to 400 decitex and consisting of 5 to 50 filaments.

[0007] However, in the case of the technology of Patent Document 1, the peeling noise reduction effect is not necessarily high to begin with, and furthermore, repeated engagement and peeling easily causes peeling in the adhesive layer, which in turn tends to reduce the peeling noise reduction effect of the male engaging elements made of monofilament. It is also difficult to reliably transmit the peeling noise vibrations of all male engaging elements from their bases to the damping material layer and have the vibrations attenuated by the damping material layer. Furthermore, in the case of male engaging elements made of monofilament, since the engaging elements are made of long, thick monofilaments, they tend to continue to vibrate significantly during peeling, which naturally increases the peeling noise. Moreover, even if the crackling noise emitted by male engaging elements made of monofilament is somewhat reduced, it remains an unrefined crackling noise.

[0008] In the technology of Patent Document 1, if a cross-linked adhesive is used, it is possible to reduce peeling at the adhesive layer due to repeated engagement and separation, but in that case the male hook-and-loop fastener becomes hard, making it unusable for applications such as clothing and gloves that require flexibility.

[0009] Furthermore, in the case of the technology of Patent Document 2, as in the case of the technology of Patent Document 1, the effect of reducing peeling noise is not high, and furthermore, the adhesive layer becomes more susceptible to peeling with repeated engagement and peeling, and it is difficult to reliably transmit the peeling noise vibrations of all male engaging elements from their bases to the adhesive layer, and because the male engaging elements are thick, elongated, long monofilaments, they tend to continue to vibrate significantly during peeling, and when an adhesive layer is used, increasing the amount of adhesive attached to the back surface to further reduce peeling noise makes it easy for dust to adhere to the adhesive, making it an undesirable technology from the standpoint of appearance as well.Furthermore, as in the technology of Patent Document 1, even if the crackling noise emitted by male engaging elements made of monofilaments is somewhat reduced, it remains an unrefined crackling noise. [Prior art documents] [Patent documents]

[0010] [Patent Document 1] Patent No. 4354232 [Patent Document 2] Japanese Patent Application Laid-Open No. 2007-7124 Summary of the Invention [Problem to be solved by the invention]

[0011] The present invention aims to provide a sheet with a silent male molded hook-and-loop fastener which produces extremely quiet peeling noise when the fastener is released from engagement, and which shows almost no decrease in the effect of reducing peeling noise even when engagement and release are repeated as in the above-mentioned prior art, and which does not suffer from the problem of loud peeling noise caused by the tendency of the male engaging elements to vibrate easily as they are thick, long, stretched monofilaments, and which can reliably transmit the peeling noise vibrations at the base of all male engaging elements to the sheet on the back side, and which produces a calm peeling noise that is different from a crackling noise, and which does not cause the problem of dust adhesion due to the adhesive. [Means for solving the problem]

[0012] That is, the present invention is a sheet with a male molded surface fastener, characterized in that a non-foamed resin sheet (B) is integrated onto the back surface of a male molded surface fastener (A), and that satisfies the following conditions 1) to 4). 1) The male molded surface fastener (A) comprises a resin base plate (a1) and a plurality of male engaging elements (a2) rising from the surface of the base plate (a1) and arranged in a row on the base plate (a1); 2) The male engaging elements (a2) are bent midway in the same direction as the row direction of the male engaging elements, with their tips approaching the substrate (a1), and the male engaging elements (a2) are made of the same resin as the resin constituting the substrate (a1); 3) A non-foaming resin sheet (B) is directly laminated and integrated onto the backside of the male molded hook-and-loop fastener (A). 4) The resin constituting the non-foamed resin sheet (B) is a resin mainly composed of the same type of elastomer resin as the resin constituting the male molded surface fastener (A), and the resin constituting the non-foamed resin sheet (B) has a lower hardness than the resin constituting the male molded surface fastener (A).

[0013] Preferably, in such a sheet with a male molded surface fastener, the resin constituting the male molded surface fastener (A) is a resin whose main component is either a polypropylene resin, a polyester-based elastomer resin, or a polyamide resin, and the resin constituting the male molded surface fastener (A) has a Type D durometer hardness in accordance with JIS K7215 in the range of 50 to 100, the resin constituting the non-foamed resin sheet (B) has a similar hardness in the range of 10 to 70, and the difference in hardness between the two is in the range of 20 to 60.

[0014] In such a sheet with a male molded surface fastener, the resin constituting the male molded surface fastener (A) and the resin constituting the non-foamed resin sheet (B) are preferably any one of the following 5) to 7). 5) The resin constituting the male molded surface fastener (A) is a resin mainly composed of polypropylene resin, and the resin constituting the non-foamed resin sheet (B) is a resin mainly composed of olefin-based elastomer resin. 6) The resin constituting the male molded surface fastener (A) and the resin constituting the non-foamed resin sheet (B) are both resins mainly composed of polyester-based elastomers; 7) The resin constituting the male molded surface fastener (A) is a resin mainly composed of polyamide resin, and the resin constituting the non-foamed resin sheet (B) is a resin mainly composed of polyamide elastomer resin.

[0015] Preferably, in such a sheet with a male molded surface fastener, the thickness of the substrate (a1) is 0.15 to 0.30 mm, the thickness of the non-foamed resin sheet (B) is 0.2 to 4 mm, and the thickness of the non-foamed resin sheet (B) is equal to or greater than the thickness of the substrate (a1).

[0016] Also preferably, in such a sheet with a male molded surface fastener, the male engaging element (a2) of the male molded surface fastener (A) has an inverted J-shape or Y-shape, and the height from the base plate (a1) to the top of the male engaging element (a2) is 0.2 to 1.5 mm.

[0017] More preferably, in such a sheet with male molded hook-and-loop fasteners, there are ridge-like raised portions on the surface of the substrate (a1) that are continuous in the row direction of the engaging elements (a2), the male engaging elements (a2) rise from above these ridge-like raised portions, and the row of male engaging elements (a2) is formed along the ridges of the continuous ridge-like raised portions.

[0018] The present invention also provides a method for producing a sheet with a male molded hook-and-loop fastener, which comprises setting a male molded hook-and-loop fastener (A) that satisfies the following conditions i) to iii) in a recess provided in a mold so that the male engaging element (a2) is on the bottom side of the recess, injecting a molten liquid of a non-foaming resin that satisfies the following condition iii) into the mold in this state, and removing it from the mold after cooling. i) the male molded surface fastener (A) comprises a resin base plate (a1) and a plurality of male engaging elements (a2) rising from the surface of the base plate (a1) and arranged in a row on the base plate (a1); ii) the male engaging elements (a2) are bent midway in the same direction as the row direction of the male engaging elements (a2), with their tips approaching the substrate (a1), and the male engaging elements (a2) are made of the same resin as the resin constituting the substrate (a1); iii) The resin constituting the non-foamed resin sheet (B) is a resin mainly composed of an elastomer resin of the same type as the resin constituting the male molded surface fastener (A), and the resin constituting the non-foamed resin sheet (B) has a lower hardness than the resin constituting the male molded surface fastener (A);

[0019] In such a manufacturing method, it is preferable that the resin constituting the male molded surface fastener (A) satisfies the following iv), and the non-foaming resin satisfies any one of the following v) to vii). iv) The resin constituting the male molded surface fastener (A) is a resin mainly composed of polypropylene resin, polyester elastomer resin, or polyamide resin; v) When the resin constituting the male molded surface fastener (A) is a resin mainly composed of polypropylene resin, the non-foaming resin is a resin mainly composed of olefin-based elastomer resin. vi) When the resin constituting the male molded surface fastener (A) is a resin mainly composed of a polyester-based elastomer, the non-foaming resin is a resin mainly composed of a polyester-based elastomer resin. vii) When the resin constituting the male molded surface fastener (A) is a resin mainly composed of polyamide resin, the non-foaming resin is a resin mainly composed of polyamide elastomer resin;

[0020] The present invention also provides a method for producing a sheet with a male molded hook-and-loop fastener having a non-foaming resin sheet (B) on the back surface of a male molded hook-and-loop fastener (A), which comprises pouring a molten resin that satisfies the following condition III) onto the surface of a metal roll that satisfies the following conditions I) and II) and injecting the molten resin into the cavity, and then superimposing and pressing a sheet (B) made of a non-foaming resin that satisfies the following condition III) onto the surface of the molten resin on the metal roll, and then cooling and solidifying the molten resin in this state, and then peeling it off the surface of the metal roll and pulling it out of the cavity. I) The metal roll is made by stacking thin ring-shaped dies on each other, each of which has a plurality of notches in the shape of a male engaging element carved on its outer circumference. II) A plurality of cavities for male engaging elements based on the notches are arranged in a row in the circumferential direction of the roll on the surface of the metal roll, and each cavity is bent in the row direction of the cavities midway, with its tip end approaching the surface of the metal roll; III) The non-foaming resin is a resin mainly composed of an elastomer resin of the same type as the resin constituting the molten liquid, and the non-foaming resin has a lower hardness than the resin constituting the molten liquid;

[0021] In such a production method, it is preferable that the melt satisfy the following IV) and the non-foamable resin satisfy any one of the following V) to VII). IV) The molten liquid is a resin mainly composed of any one of polypropylene resin, polyester elastomer resin, and polyamide resin; V) When the molten liquid is a resin mainly composed of polypropylene resin, the non-foaming resin is a resin mainly composed of olefin-based elastomer resin; VI) When the molten liquid is a resin mainly composed of a polyester-based elastomer resin, the non-foaming resin is a resin mainly composed of a polyester-based elastomer resin; VII) When the molten liquid is a resin mainly composed of a polyamide resin, the non-foaming resin is a resin mainly composed of a polyamide elastomer resin; Furthermore, the present invention is a method for producing a sheet with a male molded hook-and-loop fastener, which has a non-foamed resin sheet (B) on the back surface of a male molded hook-and-loop fastener (A) that satisfies the following conditions i) to ii), by superimposing and pressing a molten sheet (B) made of a non-foamed resin that satisfies the following condition iii) on the back surface of the male molded hook-and-loop fastener (A), and then cooling and solidifying the sheet. i) the male molded surface fastener (A) comprises a resin base plate (a1) and a plurality of male engaging elements (a2) rising from the surface of the base plate (a1) and arranged in a row on the base plate (a1); ii) the male engaging elements (a2) are bent midway in the same direction as the row direction of the male engaging elements, with their tips approaching the substrate (a1), and the male engaging elements (a2) are made of the same resin as the resin constituting the substrate (a1); iii) The resin constituting the non-foamed resin sheet (B) is a resin mainly composed of an elastomer resin of the same type as the resin constituting the male molded surface fastener (A), and the non-foamed resin has a lower hardness than the resin constituting the male molded surface fastener (A); In such a manufacturing method, it is preferable that the resin constituting the male molded surface fastener (A) satisfies the following iv), and the non-foaming resin satisfies any of the following v) to vii). iv) The resin constituting the male molded surface fastener (A) is a resin mainly composed of polypropylene resin, polyester elastomer resin, or polyamide resin; v) When the resin constituting the male molded surface fastener (A) is a resin mainly composed of a polypropylene-based resin, the non-foaming resin is a resin mainly composed of an olefin-based elastomer resin. vi) When the resin constituting the male molded surface fastener (A) is a resin mainly composed of a polyester-based elastomer resin, the non-foaming resin is a resin mainly composed of a polyester-based elastomer resin. vii) When the resin constituting the male molded surface fastener (A) is a resin mainly composed of polyamide resin, the non-foaming resin is a resin mainly composed of polyamide elastomer resin; [Effects of the Invention]

[0022] In the sheet with male molded surface fasteners and the manufacturing method thereof according to the present invention, the male molded surface fastener (A) is a molded surface fastener in which the base plate (a1) and the male engaging elements (a2) are made of the same resin, and therefore vibrations generated by the male engaging elements (a2) that cause peeling noise can be reliably absorbed by the base plate (a1). Furthermore, the resin that makes up the male molded hook-and-loop fastener (A) is of the same type as the non-foamed resin sheet (B) that is in close contact with its backside, and so has affinity with it, so that vibrations transmitted to the base plate (a1) of the male molded hook-and-loop fastener (A) are reliably transmitted to the non-foamed resin sheet (B) which is mainly made of elastomer resin, and are reduced. Moreover, the peeling sound is not an unpleasant crackling noise, but a low, calm sound that is gentle on the ears. Furthermore, a non-foaming resin sheet (B) made of a specific resin that has excellent adhesion to the male molded surface fastener (A) is directly laminated and integrated onto the back surface of the male molded surface fastener (A), so there is no adhesive layer even if the fastener is repeatedly engaged and disengaged, and therefore the problem of peeling at the adhesive layer does not occur.

[0023] The male engaging element (a2) of the male molded surface fastener (A) has a tapered shape when produced by drawing from a cavity. Therefore, the peeling noise of the male engaging element (a2) generated during peeling is generally smaller than that of a male engaging element made of a thick, long monofilament whose crystals are oriented in the length direction by stretching, such as a woven surface fastener.

[0024] When the non-foamed resin sheet (B) is laminated and integrated with the male hook-and-loop fastener (A) by insert molding, or when it is overlapped and pressed against the substrate (a1) of the hook-and-loop fastener while it is in a molten state during molding of the hook-and-loop fastener, it is firmly laminated and integrated directly onto the back surface of the substrate (a1), and therefore the vibrations that occur in the male engaging element (a2) when peeling, which cause the peeling sound, are reliably transmitted to the substrate (a1).

[0025] Furthermore, when the shape of the male engaging element (a2) is an inverted J-shape or Y-shape with a tapered tip, the sound generated during peeling is relatively small compared to male engaging elements that have a larger bulge than the shank at the top of the shank, such as the common T-shape, arrowhead-shape, and mushroom-shape male engaging elements used in male molded hook-and-loop fasteners.

[0026] Preferably, in the present invention, the male engaging element (a2) is relatively short compared to the male engaging elements used in conventional woven fabric hook-and-loop fasteners and molded hook-and-loop fasteners. In this case, the peeling noise itself is small. Preferably, not only the back surface but also the side surfaces of the substrate (a1) of the male molded hook-and-loop fastener (A) are bonded to the non-foaming resin sheet (B), and more preferably, the substrate (a1) is located below the front surface of the non-foaming resin sheet (B). This ensures that the vibrations of the peeling noise transmitted to the back surface of the male molded hook-and-loop fastener (A) can be reduced by the non-foaming resin sheet (B) covering the back surface and periphery of the substrate (a1). [Brief explanation of the drawings]

[0027] [Figure 1] FIG. 2 is an enlarged perspective view schematically showing a corner of an example of a sheet with a male molded surface fastener of the present invention. [Figure 2] FIG. 2 is a cross-sectional view schematically showing a part of the cross section of the sheet with male molded surface fastener of the present invention as seen from the direction of the arrow (P) in FIG. [Figure 3] FIG. 2 is a cross-sectional view schematically showing a part of the cross section of the sheet with male molded surface fastener of the present invention as seen from the direction of the arrow (Q) in FIG. [Figure 4] FIG. 10 is an enlarged perspective view schematically showing another example of the sheet with male molded surface fasteners of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0028] Next, the sheet with male molded hook-and-loop fasteners of the present invention will be described in detail with reference to the drawings. Fig. 1 is an enlarged perspective view showing a typical corner of an example of a sheet with male molded hook-and-loop fasteners of the present invention [where the male engaging elements (a2) are inverted J-shaped], Fig. 2 is a cross-sectional (side) view seen from the direction of arrow P in Fig. 1, i.e., a typical cross-sectional view seen from a direction perpendicular to the row direction of the male engaging elements (a2), and Fig. 3 is a cross-sectional (side) view seen from the direction of arrow Q in Fig. 1, i.e., a typical cross-sectional view seen from the row direction of the male engaging elements (a2). Also, Fig. 4 is an enlarged perspective view showing a typical enlarged corner of another example of a sheet with male molded hook-and-loop fasteners of the present invention [where the male engaging elements (a2) are Y-shaped].

[0029] As shown in FIG. 1, the sheet with male molded surface fastener of the present invention comprises a male molded surface fastener (A) and a non-foamed resin sheet (B) directly integrated on the back side thereof. The male molded surface fastener (A) consists of a base plate (a1) and a plurality (numerous) of inverted J-shaped male engaging elements (a2) rising from its surface, as shown in Figures 1 and 2, or a base plate (a1) and a plurality (numerous) of Y-shaped male engaging elements (a2) rising from its surface, as shown in Figure 4.

[0030] The male engaging elements (a2) rise from the surface of the substrate (a1) [preferably the surface of the ridge-like raised portion (a3) ​​formed on the surface of the substrate (a1) as shown in Figures 1 to 4 (in the present invention, the surface of the ridge-like raised portion (a3) ​​formed on the surface of the substrate is also referred to as the substrate surface)], and in some cases branch along the way to form a Y-shape, gradually tapering from the base to the tip. Preferably, as shown in Figure 1, they bend along the way in the same direction as the row direction of the male engaging elements (a2), and if they branch, as shown in Figure 4, each of the branches after branching similarly bends in the same direction as the row direction of the male engaging elements (a2) and in a direction that moves away from each other, with their tips approaching the substrate surface.

[0031] The male engaging elements (a2) preferably have a height from the base plate (a1) to the top of the male engaging elements (a2) of 0.2 to 1.5 mm, which is relatively low compared to the monofilament hook-type engaging elements used in conventional woven surface fasteners, the T-, lancet-, and mushroom-type male engaging elements commonly used in male molded surface fasteners, or the conventional inverted J-type male engaging elements, resulting in low peeling noise. More preferably, the height is 0.55 to 1.2 mm for inverted J-type engaging elements, and 0.2 to 0.6 mm for Y-type engaging elements.

[0032] The aforementioned Patent Document 1 provides a detailed description of the woven hook-and-loop fastener, which is its main objective, but also briefly touches on molded hook-and-loop fasteners. However, the Patent Document pays little attention to molded hook-and-loop fasteners, and does not consider at all what or how to modify the molded hook-and-loop fastener to reduce peeling noise. It simply describes attaching a rubber layer to the backside with an adhesive, which alone does not significantly reduce peeling noise. Furthermore, when a rubber layer is attached to the backside of a woven fabric with an adhesive, repeated engagement and release easily causes peeling at the adhesive layer, reducing the effectiveness of reducing peeling noise. Using a cross-linkable adhesive improves adhesion, but conversely, it hardens the hook-and-loop fastener, making it unsuitable for applications requiring flexibility, such as clothing.

[0033] A specific method for producing the male molded surface fastener (A) used in the present invention involves pouring a molten resin in the form of a sheet onto the surface of a metal roll having a large number of cavities in the shape of male engaging elements on its surface, forcing the molten resin into the cavities, and after cooling and solidifying, peeling the sheet from the metal roll surface and simultaneously pulling it out of the cavities to produce a sheet having a large number of male engaging elements (a2) on its surface.

[0034] To explain the manufacturing method of pulling out from this cavity in more detail, a ring-shaped mold 0.2 to 0.5 mm thick with cutouts in the shape of male engaging elements (a2), such as an inverted J or Y shape, carved on its outer circumference is stacked in order with a metal ring that does not have such cutouts, to prepare a mold roll having a large number of cavities with cutouts in the shape of male engaging elements on its outer surface.

[0035] In the case of a male engaging element that can be engaged in one direction, such as an inverted J-shape, it is preferable to replace half of the ring-shaped dies with ring-shaped dies having a thickness of 0.2 to 0.5 mm and having an inverted J-shaped notch cut on the outer circumference that is curved in the opposite direction to the inverted J-shape. In this case, the inverted J-shaped ring dies curved in the opposite direction and the inverted J-shaped ring dies curved in the forward direction may be alternated, or two or more ring dies may be alternated.

[0036] On the surface of such a metal roll, a plurality of cavities curved in the circumferential direction of the roll are arranged in rows in the circumferential direction, and such rows exist in parallel in the width direction of the metal roll, and in the case of an inverted J-shape, the direction of curvature of the cavities is reversed for each row or for each set of rows. In this case, whether in the inverted J-shape or the Y-shape, the cavities become thinner from the metal roll surface to the tip, and gradually curve in the circumferential direction of the metal roll from the middle, with the tip facing in a direction approaching the metal roll surface.

[0037] A specific method for pouring and molding molten resin onto the surface of a metal roll involves forcing molten resin into the gap between the metal roll and another drum roll located opposite the metal roll, and compressing it to force the molten resin into the cavity and form a sheet of uniform thickness on the roll surface; while the mold roll is rotating, a refrigerant is constantly circulating inside the roll to cool and solidify the molten resin in the cavity; the substrate (a1) of the resulting male molded surface fastener is stretched by nip rollers with the gap adjusted so that it has a uniform thickness; the cooled sheet is then peeled off from the mold roll surface, and the male engaging elements (a2) are pulled out from the cavity.

[0038] This results in a sheet-like material having a large number of male engaging elements (a2) on its surface, i.e., a male molded surface fastener (A). In order to improve the bonding strength with the non-foamed resin sheet (B) that is integrated with the back surface of the substrate (a1), the surface of the drum roll may be provided with irregularities so that the back surface of the substrate (a1) has irregularities.

[0039] The resin constituting such a male molded hook-and-loop fastener (A) is a resin mainly composed of the same type of elastomer resin constituting the non-foaming resin sheet (B), from the viewpoint of adhesion to the non-foaming resin sheet (B) which is directly laminated and integrated onto the back surface of the substrate (a1), and also from the viewpoint of reducing peeling noise. In the present embodiment, the term "mainly" in "resin Y mainly composed of X" means that among the resins contained in the resin Y, X has the largest content (mass), and the content of X in the resin Y may be 50% by mass or more, 80% by mass or more, 90% by mass or more, or even 100% by mass. In the present embodiment, "Z-based resin" means that the structural unit Z has the largest content (mass) of all the structural units of the Z-based resin, and the content of the structural unit Z in the Z-based resin may be 50% by mass or more, 80% by mass, 90% by mass or more, or even 100% by mass. The same applies to "Z-based elastomer."

[0040] In particular, since peeling noise can be reduced, preferred specific examples are resins mainly made of non-elastomer polypropylene resin, resins mainly made of polyester-based elastomer resin, and resins mainly made of non-elastomer polyamide resin. Among these, resins mainly made of polyester-based elastomer resin are particularly preferred because they can most significantly exhibit the effects of the present invention.

[0041] From the viewpoint of moldability and engaging force of the male molded surface fastener, it is preferable that the resin constituting the male molded surface fastener (A) have a Type D durometer hardness in accordance with JIS K7215 in the range of 50 to 100. If the resin is softer than this range, the resulting male molded surface fastener will be prone to wavy substrate (a1), tearing in places, and bending of the engaging elements. Conversely, if the resin is harder than this range, the male engaging elements will be prone to breaking or cracking when pulled out of the mold. Furthermore, the resulting male molded surface fastener will be too hard and unsuitable for applications requiring flexibility. Furthermore, it will be prone to shearing the loop engaging elements of the mating loop surface fastener, causing durability problems. More preferably, the durometer hardness is in the range of 50 to 75, and particularly preferably in the range of 60 to 70.

[0042] When a non-elastomeric polypropylene resin is used as the resin constituting the male molded surface fastener (A), not only is peeling noise reduced, but the male engaging elements (a2) of the resulting male molded surface fastener are less likely to break even after repeated engagement and peeling, and excellent engaging force is obtained. Such a polypropylene resin may be blended with a small amount of a resin that does not impair the performance of the polypropylene resin, such as a polyolefin resin such as polyethylene. In terms of ease of removal from the cavity, bonding to the non-foamed resin sheet (B) integrated on the back surface, and reducing peeling noise itself, it is preferable to blend a small amount of an olefinic elastomer resin, such as ethylene-propylene rubber or a block copolymer of styrene and a hydrogenated conjugated diene. The blended amount is preferably an amount that satisfies the JIS K 7215 Type D durometer hardness range of 50 to 100, for example, 2 to 15% by mass of the polypropylene resin. The male molded surface fastener may contain various stabilizers, flame retardants, colorants, etc. as needed. The amount of these additives is preferably 1 to 50% by mass of the resin that constitutes the male molded surface fastener.

[0043] When the male molded surface fastener (A) is made of a resin mainly composed of a polyester elastomer resin, the polyester elastomer resin used for molding it is preferably a resin having butylene terephthalate units as the main repeating unit copolymerized with polyoxytetramethylene glycol, which has a high elastic modulus yet retains the properties of an elastic polymer. Therefore, a male molded surface fastener made from such a resin is capable of reducing peeling noise, has high engaging force, and is extremely unlikely to tear the male engaging elements (a2) or cut the mating loop-shaped engaging elements during engagement and peeling, making it the most preferred resin for use in the male molded surface fastener of the present invention.

[0044] Furthermore, the polyester elastomer resin used in the male molded surface fastener preferably has a high proportion of polybutylene terephthalate, which is the hard segment, and a low proportion of polyoxytetramethylene glycol, which is the soft segment, so that the type D durometer hardness conforming to JIS K7215 is in the range of 50 to 100.

[0045] Polyester elastomer resins with various durometer hardnesses, from high to low, are commercially available, and one that satisfies the above-mentioned durometer hardness can be selected from these. When a polyester elastomer resin with such a durometer hardness is used, the male molded surface fastener obtained not only reduces peeling noise, but also has the advantages of the male engaging elements (a2) being less likely to break even with repeated engagement and peeling, providing excellent engaging force, and not tearing at the perforations even when the obtained male molded surface fastener is attached by sewing.

[0046] Such a resin mainly composed of a polyester-based elastomer resin may be blended with a small amount of other resin, such as a polyester resin, as long as the blend does not impair performance. Various stabilizers, flame retardants, colorants, etc. may be added to the male molded surface fastener as needed. The amount of these additives added is preferably 1 to 50% by mass of the resin constituting the male molded surface fastener. The durometer hardness referred to in the present invention is the value when the fastener is made of only the resin before the addition of such additives.

[0047] Furthermore, in the present invention, when a resin mainly composed of polyamide resin is used as the resin for molding the male molded hook-and-loop fastener (A), examples of the polyamide resin to be used include nylon 6, nylon 66, nylon 11, nylon 12, etc., and among these, nylon 6 is excellent in flexibility and moldability, and further nylon 6 is a preferred example because it not only reduces peeling noise, but also prevents the engaging element (a2) from breaking when pulled out from the cavity during molding, prevents the engaging element (a2) from breaking due to engagement and peeling, provides excellent engaging force, and does not cut the mating loop-shaped engaging element.

[0048] These polyamide resins are also commercially available in a wide range of hardness, from high to low durometer hardness, due to modification or other factors. A small amount, for example, 15% by mass or less of an elastomer resin may be blended into the resin, provided that the Type D durometer hardness conforming to JIS K7215 is within the range of 50 to 100. Of course, even in the case of this resin, various stabilizers, flame retardants, colorants, etc. may be added as needed. The amount of such additives is preferably 1 to 50% by mass of the resin constituting the male molded surface fastener.

[0049] As shown in Figures 1, 2 and 4, the male molded hook-and-loop fastener (A) obtained from such a resin has male engaging elements (a2) that become thinner from the base to the tip (i.e., thick at the base and thinner as they approach the tip), and gradually bend from the middle so that the tip points in a direction approaching the substrate (a1). Multiple male engaging elements (a2) are lined up in a row in the same direction as the bending direction of the male engaging elements (a2), and in the case of inverted J-shaped male engaging elements, the bending direction is opposite for each row or for each set of rows.

[0050] In addition, in the present invention, it is preferable that the cross-sectional shape of the top of the male engaging element (a2) is such that the width of the male engaging element (a2) is greater than the thickness of the male engaging element. To explain this more specifically, this means that the width (W) of the male engaging element at the top of the male engaging element shown in Figures 2 and 3 is greater than the thickness (S) of the male engaging element, i.e., W>S. By satisfying this, when the male molded surface fastener (A) is molded, it is possible to prevent the male engaging element (a2) from being cut when pulled out of the cavity, or to prevent cracks from occurring at the bent portion of the engaging element (a2), and it also prevents the loop fibers of the mating engaging element from being cut.

[0051] 2 and 3, the preferred size of the male engaging element (a2) in the present invention is as follows: the height of the male engaging element (a2) [i.e., the height H from the substrate (a1) to the top of the male engaging element (a2)] is 0.2 to 1.5 mm, more preferably 0.55 to 1.2 mm if the male engaging element (a2) is inverted J-shaped, or 0.2 to 0.6 mm if the male engaging element (a2) is Y-shaped, the base spread (C) is 0.2 to 1.0 mm, more preferably 0.25 to 0.8 mm, and the C / H ratio is 0.6 to 2.5, more preferably 0.65 to 2.0. In this way, a thick base and a thin tip of the engaging element and a low height of the engaging element (a2) are preferred in terms of the resistance of the engaging element (a2) to tipping, the engaging force, and the small peeling noise.

[0052] Furthermore, when the male engaging element (a2) is inverted J-shaped, it is preferable that the spread (D shown in Figure 2) at a point 2 / 3 of the height of the engaging element from the base is 0.15 to 0.4 mm, and that the male engaging element (a2) gradually begins to bend from approximately 1 / 2 to 3 / 4 of the height of the engaging element from the base.

[0053] On the other hand, when the male engaging element (a2) is Y-shaped, it preferably branches off at approximately 60 to 80% of the height H from the substrate (a1), with each branch extending away from the other branch and bending in a direction parallel to the substrate (a1), and the tip portion bending in a direction approaching the substrate (a1).

[0054] Furthermore, the width (W) of the male engaging element (a2) at its top as shown in Figure 3 is preferably 0.15 to 0.4 mm whether it is an inverted J-shape or a Y-shape, and the width of the male engaging element (a2) may be constant from the base to the tip of the male engaging element, or may become thinner toward the tip. However, when the ring-shaped mold described above is used, the width of the male engaging element (a2) will inevitably be almost constant from the base to the tip of the male engaging element (a2). The thickness (S) of the male engaging element (a2) at its top is preferably 0.1 to 0.3 mm, which is smaller than the above W.

[0055] The substrate (a1) from which the male engaging elements (a2) stand is preferably 0.15 to 0.30 mm thick (excluding the ridge-like raised portions (a3)) to ensure flexibility and strength that allows it to conform to curved surfaces. Furthermore, if the thickness is greater than this range, it is difficult for the molten resin to penetrate to the tip of the cavity during molding, making it difficult to obtain a perfectly shaped male engaging element (a2). A more preferred range is 0.2 to 0.28 mm. The density of the male engaging elements (a2) present on such a substrate (a1) is 60 to 160 pieces / cm 2 , especially 80-140 pieces / cm 2 The range is preferred.

[0056] In the male molded surface fastener (A), as shown in Figures 1 and 4, a plurality of such male engaging elements (a2) are arranged in a row in the same direction as the bending direction of the male engaging elements (a2), and as shown in Figure 2, the spacing (E) between adjacent male engaging elements in the row direction is preferably 1.2 to 2.2 mm, i.e., one male engaging element is present every 1.2 to 2.2 mm of row length, more preferably every 1.3 to 1.8 mm.

[0057] Furthermore, the interval between adjacent rows of engaging elements (the interval between adjacent rows including one row of engaging elements) is preferably in the range of 0.4 to 1.0 mm, i.e., one row of male engaging elements is present on the substrate (a1) having a width of 0.4 to 1.0 mm, and more preferably, one row of male engaging elements is present in a width of 0.5 to 0.8 mm.

[0058] As mentioned above, it is preferable that the male engaging elements (a2) rise from the surface of the ridge-like raised portion (a3) ​​formed on the surface of the substrate (a1), and to achieve this, a method is used in which the diameter of the ring-shaped mold for the engaging elements is made slightly smaller than the diameter of a ring-shaped mold without the engaging elements, or the center of the ring-shaped mold is shifted, etc. In this case, the height of the ridge-like raised portion (a3) ​​is preferably 2 to 20% of the height (H) of the male engaging elements.

[0059] In the present invention, it is not necessary for all male engaging elements (a2) to rise from the surface of the ridge-like raised portion (a3) ​​formed on the surface of the substrate. Even if some of the male engaging elements (a2) rise from the surface of the ridge-like raised portion (a3), a certain degree of effect can be obtained. Preferably, 30% or more of all male engaging elements rise from the surface of the ridge-like raised portion (a3).

[0060] A non-foaming resin sheet (B) is integrated with the back surface of such a male molded surface fastener (A). The non-foaming resin sheet (B) is not integrated with the back surface of the male molded surface fastener (A) via an adhesive or pressure-sensitive adhesive, but is directly laminated and integrated.

[0061] There are three suitable methods for obtaining a sheet in which a non-foamed resin sheet (B) is directly laminated and integrated onto the back surface of a male molded surface fastener (A).

[0062] [First Method] A method for producing a sheet with a male molded hook-and-loop fastener, comprising: setting a male molded hook-and-loop fastener (A) that satisfies the following conditions i) to iii) in a recess provided in a mold so that the male engaging element (a2) is on the bottom side of the recess; in this state, injecting a molten liquid of a non-foaming resin that satisfies the following condition iii) into the mold; and removing it from the mold after cooling. i) The male molded surface fastener (A) comprises a resin base plate (a1) and a plurality (a large number) of male engaging elements (a2) rising from the surface of the base plate (a1) and arranged in a row on the base plate (a1); ii) the male engaging elements (a2) are bent midway in the same direction as the row direction of the male engaging elements (a2), with their tips approaching the substrate (a1), and the male engaging elements (a2) are made of the same resin as the resin constituting the substrate (a1); iii) The resin constituting the male molded hook-and-loop fastener (A) is a resin mainly composed of either a polypropylene resin, a polyester-based elastomer resin, or a polyamide resin, and the non-foamed resin is a resin mainly composed of an elastomer resin of the same type as the resin constituting the male molded hook-and-loop fastener (A).

[0063] [Second Method] A method for producing a sheet with a male molded hook-and-loop fastener having a non-foaming resin sheet (B) on the back surface of a male molded hook-and-loop fastener (A), comprising the steps of: pouring a molten resin that satisfies the following condition III) onto the surface of a metal roll that satisfies the following conditions I) and II) while forcing the molten resin into the cavity; then superimposing and pressing a sheet made of a non-foaming resin that satisfies the following condition III) onto the surface of the molten resin on the metal roll; cooling and solidifying the molten resin in this state; then peeling it from the surface of the metal roll and pulling it out of the cavity. I) The metal roll is made by stacking thin ring-shaped dies on each other, each of which has a plurality (a large number) of notches in the shape of a male engaging element carved on its outer circumference. II) A plurality (a large number) of cavities for male engaging elements based on the cuts are arranged in a row in the circumferential direction of the roll on the surface of the metal roll, and each cavity is bent in the row direction of the cavities midway, with its tip end approaching the surface of the metal roll; III) The resin constituting the molten liquid is a resin mainly composed of any one of polypropylene resin, polyester-based elastomer resin, and polyamide resin, and the non-foaming resin is a resin mainly composed of an elastomer resin of the same type as the resin constituting the molten liquid; [Third Method] A method for producing a sheet with a male molded hook-and-loop fastener having a non-foaming resin sheet (B) on the back surface of a male molded hook-and-loop fastener (A) that satisfies the following conditions i) to ii), by superimposing and pressing a molten sheet (B) made of a non-foaming resin that satisfies the following condition iii) on the back surface of the male molded hook-and-loop fastener (A), and then cooling and solidifying the sheet. i) The male molded surface fastener (A) comprises a resin base plate (a1) and a plurality (a large number) of male engaging elements (a2) rising from the surface of the base plate (a1) and arranged in a row on the base plate (a1); ii) the male engaging elements (a2) are bent midway in the same direction as the row direction of the male engaging elements, with their tips approaching the substrate (a1), and the male engaging elements (a2) are made of the same resin as the resin constituting the substrate (a1); iii) The resin constituting the non-foamed resin sheet (B) is a resin mainly composed of an elastomer resin of the same type as the resin constituting the male molded surface fastener (A), and the non-foamed resin has a lower hardness than the resin constituting the male molded surface fastener (A);

[0064] Specifically, the first method is a method in which a pre-molded male molded surface fastener (A) is set in a mold and, in that state, a resin for the non-foaming resin sheet (B) is injected into the mold and molded, thereby directly laminating and integrating the non-foaming resin sheet (B) onto the back surface of the male molded surface fastener (A); on the other hand, the second method is a method in which, when molding the male molded surface fastener (A), a pre-molded non-foaming resin sheet (B) is superimposed and pressed onto the back surface of the substrate (a1) of the resulting male molded surface fastener (A) before the substrate (a1) solidifies, thereby directly laminating and integrating the non-foaming resin sheet (B) onto the back surface of the male molded surface fastener (A); and the third method is a method in which a pre-molded male molded surface fastener (A) is superimposed and pressed onto the back surface of the pre-molded male molded surface fastener (A) while the non-foaming resin sheet (B) is in a molten state, thereby directly laminating and integrating the non-foaming resin sheet (B) onto the back surface of the male molded surface fastener (A).

[0065] In addition to the above-mentioned first to third methods, other methods include, for example, a method in which the back surface of the substrate (a1) of a pre-formed male molded hook-and-loop fastener (A) and the joining surface of the non-foamed resin sheet (B) are heated to near their melting temperatures, and then the heated surfaces of the male molded hook-and-loop fastener (A) and the non-foamed resin sheet (B) are overlapped and pressed together to form an integrated body; and a method in which, when forming the male molded hook-and-loop fastener (A), a molten resin for the non-foamed resin sheet (B) is extruded in a sheet form onto the back surface of the substrate (a1) before it solidifies, and then the two are overlapped and pressed together to form an integrated body. However, the above-mentioned first to third methods, and particularly the second and third methods, are preferred because they allow for the easy production of a homogeneous integrated laminate. However, in the case of the second method, when molding the male molded hook-and-loop fastener (A), the presence of the non-foamed resin sheet (B) pressed against the back side may make it difficult to press the resin all the way to the tip of the cavity, so the above-mentioned third method is most preferable.

[0066] In the first method described above, the back side of the substrate (a1) of the male molded surface fastener (A) melts due to the heat from the molten non-foaming resin, and because it has excellent compatibility with the non-foaming resin liquid, it is fused to the surface of the non-foaming resin sheet (B), resulting in a strong laminated integration.

[0067] In the second method described above, the surface of the non-foamed resin sheet (B) that comes into contact with the male molded surface fastener (A) melts due to the heat from the molten resin for the male molded surface fastener (A), and because it has excellent compatibility with the molten resin for the male molded surface fastener (A), it is fused together and firmly laminated together. In the case of the third method described above, the surface of the male molded hook-and-loop fastener (A) that comes into contact with the non-foaming resin sheet (B) melts or softens due to the heat from the molten resin for the non-foaming resin sheet (B), and since it has excellent compatibility with the molten resin of the non-foaming resin sheet (B), it fuses with the non-foaming resin sheet (B) and is firmly laminated and integrated.

[0068] In the case of the first method, the molten liquid of the non-foaming resin easily penetrates up to the male engaging element surface of the male molded hook-and-loop fastener (A), which can easily cause the male engaging elements (a2) to become buried in the non-foaming resin, and measures must be taken to prevent this, whereas in the case of the second and third methods, such measures do not need to be taken, and therefore it can be said that the second and third methods are superior in terms of productivity. On the other hand, the first method has the advantage that it is easy to manufacture a quieter product in which the male molded hook-and-loop fastener (A) is sunk into the non-foaming resin sheet (B), and furthermore the thickness and shape of the non-foaming resin sheet (B) can be freely changed.

[0069] The resin for the non-foamed resin sheet (B) and the resin for the male molded hook-and-loop fastener (A) must meet the following conditions: the resin constituting the non-foamed resin sheet (B) must be a resin mainly composed of an elastomer resin of the same type as the resin constituting the male molded hook-and-loop fastener (A), and the resin constituting the non-foamed resin sheet (B) must be a resin with a lower hardness than the resin constituting the male molded hook-and-loop fastener (A).

[0070] As specific examples of elastomer resins of the same type as the resin constituting the male molded hook-and-loop fastener (A), when the resin constituting the male molded hook-and-loop fastener (A) is a resin mainly composed of non-elastomer polypropylene resin, the resin constituting the non-foamed resin sheet (B) can be a resin mainly composed of olefin-based elastomer resin; when the resin constituting the male molded hook-and-loop fastener (A) is a resin mainly composed of polyester-based elastomer resin, the resin constituting the non-foamed resin sheet (B) can be a resin mainly composed of polyester-based elastomer resin; and when the resin constituting the male molded hook-and-loop fastener (A) is a resin mainly composed of non-elastomer polyamide resin such as nylon 6, the resin constituting the non-foamed resin sheet (B) can be a resin mainly composed of polyamide-based elastomer resin.

[0071] These combinations have the advantages of being quiet, having excellent peel resistance between the male molded hook-and-loop fastener (A) and the non-foamed resin sheet (B), and also having excellent flexibility in the joined integrated sheet. In particular, in order to enhance the effect of reducing peeling noise, it is preferable that the resin constituting the non-foamed resin sheet (B) has a Type D durometer hardness conforming to JIS K7215 within the range of 10 to 70, and the difference in Type D durometer hardness conforming to JIS K7215 with the resin constituting the male molded surface fastener is within the range of 20 to 60. Most preferably, the hardness of the resin constituting the non-foamed resin sheet (B) is within the range of 20 to 45, and the difference in Type D durometer hardness conforming to JIS K7215 with the resin constituting the male molded surface fastener is within the range of 25 to 50.

[0072] Next, the combination of the above resins will be explained. First, in the case of the combination of the above polypropylene resin and olefin-based elastomer resin, when the resin constituting the male molded surface fastener (A) is a resin mainly composed of polypropylene resin, a resin mainly composed of olefin-based elastomer resin is used as the resin constituting the non-foamed resin sheet (B).

[0073] Examples of olefin-based elastomers include resins containing polyolefins such as polypropylene and polyethylene as the hard segment component and olefin-based rubbers such as ethylene-propylene rubber as the soft segment component, and block copolymers containing polystyrene as the hard segment component and hydrogenated polyolefins of conjugated dienes as the soft segment component. The hardness can be adjusted by changing the ratio of the hard and soft segment components. Polypropylene or polystyrene resins may be blended into the olefin-based elastomer resin to achieve the desired hardness. A mass ratio of the olefin-based elastomer resin to the polypropylene or polystyrene resin is preferably in the range of 50:50 to 100:0 from the viewpoints of quietness, sewability, flexibility, etc. Furthermore, the olefin-based elastomer resin constituting the non-foamed sheet (B) preferably contains an appropriate amount of inorganic fine particles such as barium sulfate or carbon black. The preferred amount is 10 to 80% by mass, more preferably 20 to 50% by mass.

[0074] Next, regarding the case of a combination of polyester-based elastomer resins, since they are the same polyester-based elastomer resins, if the thickness of the substrate (a1) is increased when manufacturing the male molded hook-and-loop fastener (A), a product of the same thickness as one having a non-foamed resin sheet integrated on the back surface can be obtained, which is considered rational because it saves the effort of laminating and integrating a non-foamed resin sheet on the back surface.However, the present invention cannot be achieved with a combination of resins of the same hardness.

[0075] That is, as mentioned above, the polyester elastomer resin constituting the male molded surface fastener and the polyester elastomer resin constituting the backside non-foamed resin sheet (B) must have different hardnesses. In other words, if the backside non-foamed resin sheet (B) is made from the polyester elastomer resin constituting the male molded surface fastener (A), a satisfactory reduction in peeling noise cannot be obtained, and conversely, if the male molded surface fastener (A) is made from the polyester elastomer resin constituting the backside non-foamed resin sheet (B), the moldability will be poor, the base plate (a1) will have ripples and cracks, and a surface fastener with sufficient engaging force will not be obtained. Furthermore, as will be described later, it is preferable that an appropriate amount of inorganic fine particles such as barium sulfate or carbon black is added to the resin mainly composed of a polyester-based elastomer resin used in the non-foamed resin sheet (B), the appropriate amount being within the range of 10 to 80% by mass, more preferably 20 to 50%. When such a resin is used in the male molded surface fastener (A), it is particularly difficult for the resin to penetrate to the tip of the cavity.

[0076] The polyester elastomer resin used in the non-foamed resin sheet (B) preferably has a low content of polybutylene terephthalate, which is a hard segment, and a high content of polyoxytetramethylene glycol, which is a soft segment, so that the durometer hardness (type D) according to JIS K7215 satisfies the range of 10 to 70.

[0077] Regarding such polyester-based elastomer resins, those that satisfy the above-mentioned durometer hardness can be selected from commercially available products. Using polyester-based elastomer resins with such durometer hardness not only reduces peeling noise, but also has the advantage of preventing tearing at perforations even when a hook-and-loop fastener is attached by sewing, due to the presence of the high-hardness substrate (a1). Resins primarily composed of such polyester-based elastomer resins may be blended with small amounts of other resins, such as polyester resins, within the range that does not impair performance and does not deviate from the above-mentioned hardness range.

[0078] Next, regarding the combination of polyamide resin and polyamide-based elastomer resin, polyamide-based elastomer resin is an elastomer having a polyamide block such as nylon 6 block, nylon 11 block, or nylon 12 block as the hard segment component and a polyether such as polyethylene glycol or polytetramethylene glycol or an aliphatic polyester as the soft segment component. By changing the structural units of the hard segment component and the soft segment component and by changing the ratio, various hardnesses can be obtained, and these are commercially available. One can simply select one that satisfies the above hardness range. Furthermore, a resin mainly composed of a polyamide-based elastomer resin may also be mixed with a non-elastomeric polyamide resin within the above hardness range. The resin constituting the non-foamed resin sheet (B) may contain an appropriate amount of fillers such as barium sulfate powder or calcium carbonate powder, various stabilizers, flame retardants, colorants, etc. The appropriate amount is within the range of 10 to 80% by mass, more preferably 20 to 50%.

[0079] In the present invention, preferably, not only the back surface but also the side surfaces of the substrate (a1) are directly bonded to the resin constituting the non-foaming resin sheet (B), as shown in Figs. 1 to 3, and more preferably, the substrate (a1) of the male molded surface fastener (A) is located below the surface of the non-foaming resin sheet (B) (i.e., the substrate (a1) is recessed into the non-foaming resin sheet (B)), as shown in Figs. 1 to 3.

[0080] Since the side surfaces of the substrate (a1) are also directly bonded to the resin constituting the non-foaming resin sheet (B), the sound generated when the male molded surface fastener (A) is peeled off can be more effectively reduced. Furthermore, since the substrate (a1) is positioned below the surface of the non-foaming resin sheet (B), the sound can be reduced even more effectively. In order to ensure that the back surface and side surfaces of the substrate (a1) are directly bonded to the resin constituting the non-foaming resin sheet (B), it is preferable to manufacture the substrate (a1) using the first method described above.

[0081] Specifically, in the above-mentioned insert molding method, it is preferable to use a method in which the male engaging element (a2) is fitted into a recess in the mold, the male molded hook-and-loop fastener (A) is set in the mold so that the substrate (a1) protrudes from the recess, and in this state, a non-foaming resin liquid for the non-foaming resin sheet (B) is injected into the mold. Furthermore, in order to position the substrate (a1) below the surface of the non-foaming resin sheet (B), the male molded surface fastener (A) may be set in the mold so that the entire substrate (a1) protrudes from the inner wall of the mold toward the inside of the mold.

[0082] In the case of the first method, as mentioned above, when the non-foaming resin liquid is injected into the mold, the resin liquid may flow onto the male engaging element surface side of the male molded hook-and-loop fastener (A) set in the mold, covering the male engaging elements (a2) with resin and causing the engaging force to be lost. To prevent this, it is preferable to cover the male engaging element surface side with a covering material such as silicone rubber, water-soluble resin, film or nonwoven fabric before setting it in the mold.

[0083] When the side surfaces of the substrate (a1) are also directly bonded to the resin constituting the non-foaming resin sheet (B), particularly when the side surfaces of the substrate (a1) are also directly bonded to the resin constituting the non-foaming resin sheet (B) and the substrate (a1) is positioned below the surface of the non-foaming resin sheet (B), it is difficult to set the male hook-and-loop fastener in the mold and the resin liquid is likely to flow into the male engaging element surface side of the male molded hook-and-loop fastener (A) set in the mold, so it is preferable to cover the engaging element surface with a covering material. In this case, it is preferable that the covering material not cover the back surface and side surfaces of the substrate (a1).

[0084] When the male engaging element surface side is covered with a covering material, it is necessary to remove the covering material covering the male engaging element surface of the male molded hook-and-loop fastener (A) after the molded product is removed from the mold. Furthermore, instead of covering the entire male engaging element surface side, a method of covering only the periphery of the engaging elements with silicone rubber, water-soluble resin, or the like may be used.

[0085] In the present invention, the thickness of the non-foaming resin sheet (B) is preferably 0.2 to 4 mm, and the thickness of the non-foaming resin sheet (B) is preferably equal to or greater than the thickness of the substrate (a1). In such a case, the noise generated during peeling can be efficiently reduced, and the sheet with the silent male molded surface fastener has flexibility, conformability to curved surfaces, and strength. More preferably, the thickness of the non-foaming resin sheet (B) is 0.3 to 2.5 mm, and 1.2 to 15 times the thickness of the substrate (a1). Note that the thickness of the non-foaming resin sheet (B) referred to here refers to the thickness of the non-foaming resin sheet (B) only at the portion where the male molded surface fastener (A) is integrated, excluding the thickness of the male molded surface fastener (A). The resin sheet (B) must be non-foamed, and if it is foamed and porous, it will hardly exhibit the effect of reducing peeling noise.

[0086] The non-foaming resin sheet (B) may have holes for inserting metal fittings so that the hook-and-loop fastener-equipped resin sheet (B) of the present invention can be connected to metal fittings, etc., and may also be integrated with fabric, etc. on the back side to make it easier to attach by sewing.

[0087] The female hook-and-loop fastener that engages with the sheet with silent male molded hook-and-loop fasteners of the present invention can be a hook-and-loop fastener having a conventional loop-type engaging element, and in particular, a silent hook-and-loop fastener having a sound-absorbing elastomer resin layer attached to the back of the hook-and-loop fastener is preferred, and the synergistic effect of the silent male molded hook-and-loop fasteners of the present invention and the silent effect of the female hook-and-loop fastener further enhances the silent effect.

[0088] The sheet with silent male molded hook-and-loop fastener of the present invention can be used in all fields where male hook-and-loop fasteners are used, but is particularly useful in fields where quietness is required, such as infant clothing, military clothing, shoes, helmets, tents, military bindings, and other sports gloves.

[0089] Specific attachment methods include fixing the back surface of the sheet of the present invention to the object with an adhesive or pressure-sensitive adhesive, fixing to the object by sewing, or even drilling holes through the end of the sheet in the width direction and attaching metal fittings to these holes to secure the sheet to the object. In particular, the silent male molded hook-and-loop fastener of the present invention has excellent flexibility due to the presence of a sheet containing an elastomer resin on the back surface, and also has an excellent feel due to the small male engaging elements on the surface. Therefore, these properties make it suitable for attachment to clothing, etc. by sewing. As mentioned above, when the male molded hook-and-loop fastener (A) on the front side and the non-foamed resin sheet (B) on the back side are both made of polyester-based elastomer resin, they are less likely to tear at the perforations, making them suitable for use in attaching them to clothing, tools, etc. by sewing. [Example]

[0090] The present invention will be described in more detail below with reference to examples. The engaging force of the male molded hook-and-loop fastener was measured according to the method of JIS L3416, including the initial engaging force and the engaging force after 1,000 repeated peel-and-engage cycles. The loop-shaped engaging element used for this test was a polyethylene terephthalate woven hook-and-loop fastener (Magic Tape (registered trademark) B9750Y.00 manufactured by Kuraray Fastening Co., Ltd.) with a 2 mm thick sheet of polyester elastomer resin (Hytrel 3046 manufactured by Toray DuPont Co., Ltd.) bonded to the back surface using Alteco adhesive. This loop hook-and-loop fastener was replaced with a new one every 50 repeated peel-and-engage cycles.

[0091] The peeling noise at that point was also measured. The peeling noise of the hook-and-loop fastener was measured in accordance with JIS Z8731. Specifically, a sound level meter (Rion Co., Ltd., "NA-20") was used, with frequency characteristics set to A and dynamic characteristics set to AST. A 30mm x 140mm loop hook-and-loop fastener sheet was used as the mating mating member. The polyester elastomer resin sheet was adhesively bonded to the backside of a 20mm x 80mm woven hook-and-loop fastener with loop-shaped engaging elements. The measurement distance between the hook-and-loop fastener and the sound level meter was 10cm, and the sound level meter reading was read during peeling. The sound level during peeling was expressed in dB (decibels). A 10dB difference is perceived by the human ear as approximately twice the volume. This peeling noise test also involved replacing the fastener with a new one every 50 engagement and peel cycles.

[0092] Example 1 [Manufacturing of male molded hook-and-loop fastener (A)] The mold was a ring-shaped mold having a thickness of 0.20 mm and a diameter of 211.8 mm, with the shape of a hook-type engagement element (inverted J-shaped engagement element) engraved on its outer circumference; a metal ring having a thickness of 0.30 mm and a diameter of 212 mm and a flat outer surface without such an engraved shape; a ring-shaped mold having a thickness of 0.20 mm and a diameter of 211.8 mm, with the shape of a hook-type engagement element engraved on its outer circumference but facing in the opposite direction to the above-mentioned hook-type engagement element shape; and a metal ring having a thickness of 0.30 mm and a diameter of 212 mm and a flat outer surface without such an engraved shape. By stacking these molds in this order, a mold roll having a width of 120 mm and having a large number of cavities in the shape of a hook-type engagement element and cavities in the shape of a hook-type engagement element facing in the opposite direction on its outer surface was prepared.

[0093] A melt of thermoplastic polyester elastomer resin (Hytrel 6347, manufactured by DuPont-Toray Co., Ltd.; durometer hardness (type D): 63) was extruded into the gap between the mold roll and another drum roll positioned opposite the mold roll, and the resin was filled into the cavity by compression, forming a sheet of uniform thickness on the roll surface. While the mold roll was rotating, the resin in the cavity was cooled by water constantly circulating inside the roll, and then the resin was stretched using nip rolls with the gap adjusted to a substrate thickness of 0.20 mm, and the cooled and solidified sheet was peeled off from the mold roll surface, producing a male molded surface fastener (A).

[0094] Only the surface of the male engaging elements of the male molded surface fastener (A) thus obtained was covered with silicone rubber, and then cut into a size of 80 mm in length in the row direction of the male engaging elements and 20 mm in width. Next, this male molded hook-and-loop fastener (A) was set in a recess in the mold so that the male engaging elements were facing the bottom of the recess and so that the hook-and-loop fastener substrate protruded from the recess and even protruded from the inner wall surface of the mold. Then, a molten liquid consisting of 70 parts by mass of thermoplastic polyester elastomer resin (Hytrel 3046 manufactured by Toray DuPont Co., Ltd.: durometer hardness (type D): 27) and 30 parts by mass of barium sulfate was poured into the mold, cooled, and then removed from the mold. The silicone rubber covering the surface of the hook-and-loop fastener was then removed.

[0095] The sheet with the obtained male molded surface fastener had a shape as shown in Figure 1, i.e., the inverted J-shaped male molded surface fastener gradually became thinner from the base to the tip and gradually curved halfway, with the tip having a large number of male engaging elements (a2) pointing in a direction slightly closer to the substrate, and furthermore, multiple male engaging elements (a2) were lined up in a row in the same direction as the bending direction of the inverted J-shaped male engaging elements, and furthermore, the bending direction was opposite for each row.

[0096] The shape of the male engaging element (a2) of the male molded hook-and-loop fastener was as shown in Figure 1, with its height (H) being 0.90 mm from the surface of the substrate, and the lower end of the tip of the male engaging element being closer to the substrate by a distance equivalent to 5% of the height (H) of the male engaging element compared to the height of the lower end of the male engaging element at the top. The width (W) of the male engaging element at the top was 0.20 mm, the thickness (S) of the male engaging element at the top was 0.09 mm, the spread (C) of the base of the engaging element was 0.76 mm, the male engaging element (a2) gradually began to bend from about 2 / 3 of the height of the engaging element from the base, and the density of the male engaging elements (a2) was 136 pieces / cm. 2 The thickness of the substrate was 0.20 mm, the interval (E) between adjacent male engaging elements in the row direction was 1.50 mm, and the interval between adjacent engaging element rows was 0.50 mm. Furthermore, on the surface of the substrate, there were ridge-like raised portions with a height of 0.10 mm that continued in the row direction of the male engaging elements as shown in FIGS. 1 to 3, and the male engaging elements stood up from these ridge-like raised portions.

[0097] The sheet (B) comprised a soft polyester elastomer resin and barium sulfate, with the male molded hook-and-loop fastener integrated onto its surface, was 2.2 mm thick. The male molded hook-and-loop fastener (A) was directly laminated and integrated onto the surface of the sheet (B) with the male engaging element facing outward. Surrounding the male molded hook-and-loop fastener (A) were two exposed areas, each 5 mm wide (corresponding to the 20 mm length of the hook-and-loop fastener) and 5 mm wide and 55 mm wide (corresponding to the 40 mm width). The back and side surfaces of the substrate were both directly bonded to the resin constituting the sheet (B), with the surface of the hook-and-loop fastener (A) recessed from the surface of the sheet. The engagement force and maximum sound pressure (dB) of the peeling noise between 2 and 20 kHz of the resulting sheet with male molded hook-and-loop fasteners were measured. The results are shown in Table 1.

[0098] Comparative Example 1 In the above Example 1, the engaging force and the maximum sound pressure (dB) of the peeling sound at frequencies between 2 and 20 kHz were measured in the state of the male molded surface fastener without integrating the non-foamed resin sheet (B) on the back surface of the male molded surface fastener (A). The results are also shown in Table 1.

[0099] Comparative Example 2 A sheet with a male molded hook-and-loop fastener was obtained in the same manner as in Example 1 above, except that the resin to be injected into the mold in which the male molded hook-and-loop fastener (A) was set was a resin consisting of 70 parts by mass of the same thermoplastic polyester elastomer resin (Hytrel 6347 manufactured by DuPont-Toray Co., Ltd.: durometer hardness 63) and 30 parts by mass of barium sulfate, which was the same as that used to manufacture the male molded hook-and-loop fastener (A).Then, as in Example 1, the engaging force and the maximum sound pressure (dB) of the peeling sound in the frequency range of 2 to 20 kHz were measured.The results are also shown in Table 1.

[0100] Comparative Example 3 The same procedure was followed as in Example 1, except that the resin used to manufacture the male molded hook-and-loop fastener (A) was the same thermoplastic polyester elastomer resin (Hytrel 3046, manufactured by DuPont-Toray Co., Ltd., with a durometer hardness of 27) as the sheet to be integrated onto the back surface. However, during the molding stage of the male molded hook-and-loop fastener (A), damage and waving occurred in the substrate of the hook-and-loop fastener (A) when it was peeled from the roll surface. Then, using a portion that did not suffer damage, sheet (B) was integrated onto the back surface in the same manner as in Example 1, thereby obtaining a sheet with a male molded hook-and-loop fastener. Then, as in Example 1, the engaging force and the maximum sound pressure (dB) of the peeling sound between frequencies of 2 and 20 kHz were measured. The results are shown in Table 1.

[0101] Comparative Example 4 In Example 1 above, a 2.2 mm thick sheet made of 70 parts by mass of thermoplastic polyester elastomer resin (Hytrel 3046 manufactured by Toray DuPont Co., Ltd.: durometer hardness (type D): 27) and 30 parts by mass of barium sulfate was attached to the backside of the male molded surface fastener (A) using an instant adhesive (cyanoacrylate). Then, as in Example 1, the engaging force and the maximum sound pressure (dB) of the peeling sound in the frequency range of 2 to 20 kHz were measured. The results are shown in Table 1.

[0102] [Table 1]

[0103] As is clear from Table 1 above, the sheet with male molded hook-and-loop fastener of Example 1 has extremely excellent initial engaging force and engaging force even after 100 repeated engaging and peeling cycles, and furthermore, the peeling noise during this process is extremely quiet; when peeled slowly, the sound produced is a low, calm sound similar to the sound made by bubbles on the surface of water popping continuously, which is significantly quieter than the peeling noise of conventional hook-and-loop fasteners. Furthermore, this sheet with male molded hook-and-loop fastener was attached to the surface of cotton fabric by sewing, and even after repeated engagement and release with the loop hook-and-loop fastener 2,000 times, the sheet with male molded hook-and-loop fastener did not tear at all from the perforations.

[0104] On the other hand, in the case of the male molded hook-and-loop fastener of Comparative Example 1, the engaging force was as excellent as that of Example 1, but the peeling noise was much louder than that of Example 1, although it was improved to some extent compared to woven hook-and-loop fasteners, and the noise itself was an unpleasant crackling sound, similar to the peeling noise of conventional hook-and-loop fasteners.

[0105] In the case of the male molded hook-and-loop fastener sheet of Comparative Example 2, the engagement force was as excellent as that of Example 1, but the peeling noise, although somewhat improved compared to Comparative Example 1, was still not at a satisfactory level and was not as pleasant to the ears as that of Example 1. Furthermore, the initial engaging force of Comparative Example 3 was significantly inferior to that of Example 1, and did not have the basic performance required of a general-purpose surface fastener.

[0106] In addition, although there were no problems with the engaging force in Comparative Example 4, the male molded hook-and-loop fastener sheet was harder than that in Example 1, and it cannot be said to be suitable for applications requiring flexibility.Furthermore, with regard to the peeling noise, as the engaging and peeling were repeated, the adhesive part peeled off, and the noise gradually became louder and more harsh.

[0107] Example 2 In Example 1, the resin constituting the male molded surface fastener (A) was a resin pellet (Type D durometer hardness according to JIS K7215: 60) made by adding 20% ​​by mass of an olefin-based elastomer resin (ethylene-propylene rubber with a soft segment ratio of 50% by mass) to a polypropylene resin. Furthermore, the resin for the non-foamed resin sheet (B) to be bonded and integrated to the back surface was a mixture consisting of 50 parts by mass of an olefin-based elastomer (ethylene-propylene rubber with a soft segment ratio of 50% by mass), 20 parts by mass of polypropylene, and 30 parts by mass of barium sulfate (Note: The Type D durometer hardness according to JIS K7215 for the mixed resin of olefin-based elastomer and polypropylene with the above composition is 30). A sheet with a male molded surface fastener was obtained in exactly the same manner as in Example 1. Then, as in Example 1, the engaging force and the maximum sound pressure (dB) of the peeling sound between 2 and 20 kHz were measured. The results are shown in Table 2.

[0108] Example 3 In Example 1 above, nylon 6 (Amilan U121 manufactured by Toray Industries, Inc.: Type D durometer hardness according to JIS K7215 is 95) was used as the resin constituting the male molded hook-and-loop fastener (A), and a mixture consisting of 70 parts by mass of polyamide elastomer resin (XPA product number 9068X1 manufactured by Ube Industries, Ltd.: Type D durometer hardness according to JIS K7215 is 68) and 30 parts by mass of barium sulfate was used as the resin for the non-foamed resin sheet (B) to be bonded and integrated to the backside of nylon 6. A sheet with a male molded hook-and-loop fastener was obtained in exactly the same manner as in Example 1. Then, as in Example 1, the engaging force and the maximum sound pressure (dB) of the peeling sound between frequencies of 2 and 20 kHz were measured. The results are shown in Table 2.

[0109] Comparative Example 5 A 2.5 mm thick sheet made of the same barium sulfate-containing resin as used in Example 2 was attached to the backside of the male molded surface fastener produced in Example 2 using an instant adhesive (cyanoacrylate).Then, as in Example 1, the engaging force and the maximum sound pressure (dB) of the peeling sound in the frequency range of 2 to 20 kHz were measured.The results are shown in Table 2.

[0110] Example 4 In Example 1, the height of the male engaging elements was changed to 0.4 mm, and the density of the male engaging elements was changed to 147 pieces / cm 2 Further, using a mold roll in which the bending direction of the male engaging elements was reversed in each unit, a male molded hook-and-loop fastener made of polyester-based elastomer resin was produced in the same manner as in Example 1, and a non-foamed resin sheet (B) having a thickness of 2.8 mm was bonded and integrated to the back surface of the molded hook-and-loop fastener to obtain a sheet with a male molded hook-and-loop fastener in the same manner as in Example 1.

[0111] The male molded surface fastener (A) present on the surface of the obtained sheet with male molded surface fastener has lower engaging element height, higher engaging element density, and smaller shape and arrangement than those of Example 1. The engaging force of the sheet with male molded surface fastener thus obtained and the maximum sound pressure (dB) of the peeling sound between 2 and 20 kHz were measured. The results are shown in Table 2.

[0112] Example 5 In Example 1, the sheet with a male molded hook-and-loop fastener was manufactured using the second method described above. Specifically, the same resin melt as in Example 1 was poured onto the surface of the same metal roll used in Example 1, and the melt was injected into the cavity. A 2.5 mm-thick sheet composed of 50 parts by mass of polyester elastomer resin and 30 parts by mass of barium sulfate, the same resin mixture used for the sheet in Example 1, was then superimposed and pressed onto the surface of the melt on the metal roll. The melt was then cooled and solidified, and the sheet was then peeled off the metal roll surface and pulled out of the cavity, producing a sheet with a male molded hook-and-loop fastener having a 2.3 mm-thick non-foamed resin sheet (B) on the backside of a male molded hook-and-loop fastener (A) with J-shaped engaging elements. Then, as in Example 1, the engaging force and the maximum sound pressure (dB) of the peeling noise between 2 and 20 kHz were measured. The results are shown in Table 2.

[0113] Comparative Example 6 A 2.5 mm thick natural rubber sheet (Type D durometer hardness 30 according to JIS K7215) was attached to the backside of a commercially available woven hook surface fastener [A8693Y.00 manufactured by Kuraray Fastening Co., Ltd.: the hook-shaped engaging elements are made of polyester monofilament with a diameter of 0.19 mm and a height of 1.85 mm] using instant adhesive (cyanoacrylate). The engaging force and peeling noise of this woven hook surface fastener with the natural rubber sheet attached were then measured in the same manner as in the above Examples and Comparative Examples. The results are shown in Table 2 below.

[0114] Comparative Example 7 A 2.5 mm thick natural rubber sheet (Type D durometer hardness according to JIS K7215: 30) was attached to the back surface of the male molded surface fastener produced in Example 2 using an instant adhesive (cyanoacrylate) as the adhesive, in the same manner as in Comparative Example 5. The engaging force and peeling noise of the male molded surface fastener with this natural rubber sheet were then measured in the same manner as in the above Examples and Comparative Examples. The results are shown in Table 2 below.

[0115] Example 6 In the above Example 1, a male molded surface fastener having a Y-shaped male engaging element was manufactured in the same manner as in Example 1, except that the shape of the hook-shaped engaging element carved on the outer circumference of the ring-shaped mold used as the mold was replaced with a Y-shape with the branched tip bending in the direction approaching the outer circumference.

[0116] The male engaging elements of the obtained male molded surface fastener (A) had a Y-shape as shown in Figure 4, with a height (H) of 0.4 mm from the substrate surface, and the lower end of the tip of the male engaging element was closer to the substrate by a distance equivalent to 5% of the height (H) of the male engaging element compared to the height of the lower end of the male engaging element at the top. The width (W) of the male engaging element at the top was 0.15 mm, the thickness (S) of the male engaging element at the top was 0.09 mm, and the density of the male engaging elements was 147 pieces / cm. 2The substrate thickness was 0.20 mm, the spacing (E) between adjacent male engaging elements in the row direction was 1.15 mm, and the spacing between adjacent rows of engaging elements was 0.20 mm. Furthermore, on the surface of the substrate, there was a 0.10 mm high ridge-like raised portion (a3) ​​that continued in the row direction of the male engaging elements, as shown in Figure 4. The male engaging elements (a2) rose from the top of this ridge-like raised portion (a3), and each of the Y-shaped branches also extended in the ridge direction of this ridge-like raised portion. Furthermore, the male engaging elements (a2) became thinner from the base to the tip.

[0117] A 2.5 mm-thick non-foamed resin sheet made of the same barium sulfate-containing resin as in Example 1 was directly integrated onto the back surface of this male molded hook-and-loop fastener (A) using the same molding method as in Example 1. In the resulting integrated product, there were two areas around the male molded hook-and-loop fastener (A) where the surface of the sheet was exposed without the hook-and-loop fastener being integrated: a 5 mm-wide area (corresponding to the 20 mm length of the hook-and-loop fastener) and two 5 mm-wide areas (corresponding to the 40 mm width). The back and side surfaces of the substrate were both directly bonded to the resin constituting the sheet, and the surface of the hook-and-loop fastener (A) was recessed relative to the surface of the sheet. The engaging force and the maximum sound pressure (dB) of the peeling noise between 2 and 20 kHz of the sheets with male molded hook-and-loop fasteners obtained in this manner were measured. The results are shown in Table 2.

[0118] Comparative Example 8 In Example 2, the resin for the non-foamed resin sheet (B) to be bonded and integrated to the back surface was 70 parts by mass of resin pellets (Type D durometer hardness according to JIS K7215: 65) in which 20% by mass of an olefin-based elastomer resin (ethylene-propylene rubber with a soft segment ratio of 50% by mass) was added to the polypropylene resin used to form the male molded hook-and-loop fastener (A), to which 30 parts by mass of barium sulfate was added. A sheet with a male molded hook-and-loop fastener was produced in the same manner as in Example 2. Then, as in Example 2, the engaging force and the maximum sound pressure (dB) of the peeling sound between frequencies of 2 and 20 kHz were measured. The results are shown in Table 2 below.

[0119] Comparative Example 9 In Example 3, the resin for the non-foamed resin sheet (B) to be bonded and integrated to the back surface was the same as that used to form the male molded hook-and-loop fastener (A), but this was prepared by adding 30 parts by mass of barium sulfate to 70 parts by mass of the nylon 6 resin (Amilan U121 manufactured by Toray Industries, Inc.: Type D durometer hardness according to JIS K7215 is 95) and producing a sheet with a male molded hook-and-loop fastener in the same manner as in Example 3. Then, as in Example 2, the engaging force and the maximum sound pressure (dB) of the peeling sound in the frequency range of 2 to 20 kHz were measured. The results are shown in Table 2 below.

[0120] Comparative Example 10 In Example 2, a sheet with a male molded hook-and-loop fastener was produced in the same manner as in Example 2, except that the resin constituting the male molded hook-and-loop fastener (A) was a mixture of 60 parts by mass of an olefin elastomer resin (ethylene-propylene rubber with a soft segment ratio of 50% by mass), 10 parts by mass of polypropylene, and 30 parts by mass of barium sulfate (note that the mixed resin of the above composition of olefin elastomer and polypropylene has a Type D durometer hardness of 25 according to JIS K7215). Then, as in Example 2, the engaging force and the maximum sound pressure (dB) of the peeling sound between 2 and 20 kHz were measured. The results are shown in Table 2 below.

[0121] [Table 2]

[0122] As is clear from Table 2 above, although the sheets with male molded hook-and-loop fasteners of Examples 2 and 3 were slightly inferior to that of Example 1, they still had excellent initial engagement force and engagement force even after 100 repeated engagement and peeling cycles, and the peeling noise during this process was also quiet, which was significantly quieter than the peeling noise of conventional hook-and-loop fasteners.

[0123] Furthermore, the peeling noise of Examples 4 and 5 was extremely quiet, just like Example 1, and was significantly quieter than the peeling noise of conventional hook-and-loop fasteners. The fasteners also had excellent engaging force, and this excellent performance remained almost unchanged even after repeated engagement and peeling. Furthermore, although Example 6 differs from the other Examples in the shape of the male engaging element, it was found to have excellent engaging force and the effect of reducing peeling noise, regardless of the shape of the male engaging element.

[0124] On the other hand, in the case of Comparative Example 5, although the engaging force was slightly inferior to that of Example 1, it still had an excellent value. However, with regard to the peeling noise, as the engaging and peeling were repeated, the noise gradually increased and became unpleasant to the ear. Compared to Example 2, the peeling noise after repeated use was far inferior and not satisfactory.

[0125] In addition, in Comparative Example 6, a rubber sheet was adhered to the backside of a woven hook-and-loop fastener, but the peeling noise was significantly inferior, being only slightly quieter than the crackling noise of conventional woven hook-and-loop fasteners.Furthermore, repeated engagement and peeling tended to cause the backside of the engaging element to peel off from the rubber sheet due to the tension generated during the process, making the peeling noise even louder.

[0126] In addition, in Comparative Example 7, a rubber sheet was adhered to the back surface of the molded hook-and-loop fastener, and although the peeling noise was somewhat improved compared to Comparative Example 6, it was still inferior to any of the above Examples, and when the engagement and peeling were repeated, the peeling noise became even louder, as with Comparative Example 5.

[0127] Furthermore, in both Comparative Examples 8 and 9, the resin constituting the sheet integrated on the back side is the same as the resin constituting the molded hook-and-loop fastener. However, the sheets with male molded hook-and-loop fasteners obtained in these Comparative Examples all had an extremely low effect of silencing the peeling noise, and were extremely rigid, so they could not be attached to clothing, etc., and no benefit could be found in having a silencing sheet integrated on the back side.

[0128] Furthermore, like Comparative Example 3, Comparative Example 10 had an initial engaging force that was significantly inferior to that of Example 2, and did not have the basic performance required of a hook-and-loop fastener.

[0129] Example 7 In the above Example 1, the third method was used as the method for producing a sheet with a male molded surface fastener. That is, a 2.2 mm-thick molten sheet consisting of 70 parts by mass of thermoplastic polyester elastomer resin (Hytrel 3046 manufactured by Toray DuPont Co., Ltd.: durometer hardness (type D): 27) and 30 parts by mass of barium sulfate was superimposed on the back surface of the male molded surface fastener (A) produced in Example 1, pressed together, and then cooled to obtain a male molded surface fastener (A) having a non-foamed resin sheet (B) consisting of soft polyester elastomer resin and barium sulfate integrated on its back surface. The thickness of sheet (B) in the obtained integrated product was 2.2 mm, and sheet (B) was directly laminated and integrated onto the back surface of male molded surface fastener (A), and both the back surface and side surfaces of the base material of male molded surface fastener (A) were directly bonded to the resin that constituted non-foamed resin sheet (B), with the surface of male molded surface fastener (A) positioned lower than the surface of sheet (B) in areas where male molded surface fastener (A) was not bonded. The engaging force and the volume of the peeling noise of the sheet with male molded surface fastener obtained in this way were measured. As a result, the initial engagement force was 0.23 N / cm peel, the initial peel noise was 89 DB, and after 100 engagement / peel cycles the engagement force was 0.22 N / cm peel, and the initial peel noise was 88 DB, both of which were found to have excellent engagement strength and quietness almost similar to those of Example 1. Moreover, unlike Example 1, there was no need to take any measures to prevent the resin of sheet (B) from flowing onto the engagement element surface, and the process was also excellent in terms of simplicity. [Explanation of symbols]

[0130] A: Male molded hook-and-loop fastener B: Non-foaming resin sheet a1: Substrate a2: Male engaging element a3: Ridged raised part H: Height from the substrate to the top of the male engaging element E: Distance between adjacent male engaging elements in the row direction C: Spread of the base of the male engaging element S: Thickness of the male engaging element at the top D: Spread at a point 2 / 3 of the height from the base of the male engaging element W: Width of the male engaging element at the top

Claims

1. A sheet with a male molded surface fastener, characterized in that a non-foaming resin sheet (B) is integrated onto the back surface of a male molded surface fastener (A), and the following conditions 1) to 4) are satisfied: 1) The male molded surface fastener (A) comprises a resin base plate (a1) and a plurality of male engaging elements (a2) rising from the surface of the base plate (a1) and arranged in a row on the base plate (a1); 2) The male engaging elements (a2) are bent midway in the same direction as the row direction of the male engaging elements, with their tips approaching the substrate (a1), and the male engaging elements (a2) are made of the same resin as the resin constituting the substrate (a1); 3) A non-foaming resin sheet (B) is directly laminated and integrated onto the back surface of the male molded surface fastener (A); 4) The resin constituting the non-foamed resin sheet (B) is a resin mainly composed of the resin constituting the male molded surface fastener (A) or an elastomer resin of the same type as the elastomer resin constituting the male molded surface fastener (A), and the resin constituting the non-foamed resin sheet (B) has a lower hardness than the resin constituting the male molded surface fastener (A). The type D durometer hardness of the resin constituting the male molded surface fastener (A) is in the range of 50 to 100 in accordance with JIS K7215, and the same hardness of the resin constituting the non-foamed resin sheet (B) is in the range of 10 to 70, and the difference in hardness between the two is in the range of 20 to 60.

2. 2. A sheet with male molded surface fasteners according to claim 1, wherein the resin constituting the male molded surface fastener (A) is a resin mainly composed of any one of polypropylene resin, polyester elastomer resin and polyamide resin.

3. A sheet with a male molded hook-and-loop fastener according to claim 1 or 2, wherein the resin constituting the male molded hook-and-loop fastener (A) and the resin constituting the non-foamed resin sheet (B) are any of the following 5) to 7). 5) The resin constituting the male molded surface fastener (A) is a resin mainly composed of polypropylene resin, and the resin constituting the non-foamed resin sheet (B) is a resin mainly composed of olefin-based elastomer resin. 6) The resin constituting the male molded surface fastener (A) and the resin constituting the non-foamed resin sheet (B) are both resins mainly composed of polyester-based elastomer resins; 7) The resin constituting the male molded surface fastener (A) is a resin mainly composed of a polyamide-based resin, and the resin constituting the non-foamed resin sheet (B) is a resin mainly composed of a polyamide-based elastomer resin.

4. The sheet with a male molded hook-and-loop fastener according to any one of claims 1 to 3, wherein the thickness of the substrate (a1) is 0.15 to 0.30 mm, the thickness of the non-foamed resin sheet (B) is 0.2 to 4 mm, and the thickness of the non-foamed resin sheet (B) is equal to or greater than the thickness of the substrate (a1).

5. A sheet with a male molded surface fastener according to any one of claims 1 to 4, wherein the male engaging element (a2) of the male molded surface fastener (A) has an inverted J-shape or Y-shape, and the height from the base plate (a1) to the top of the male engaging element (a2) is 0.2 to 1.5 mm.

6. A sheet with a male molded hook-and-loop fastener according to any one of claims 1 to 5, wherein the surface of the substrate (a1) has a ridge-like raised portion that is continuous in the row direction of the male engaging elements (a2), the male engaging elements (a2) rise from above this ridge-like raised portion, and the row of the male engaging elements (a2) is formed along the ridges of the continuous ridge-like raised portion.

7. A method for producing a sheet with a male molded hook-and-loop fastener, characterized in that a male molded hook-and-loop fastener (A) satisfying the following conditions i) to iii) is set in a recess provided in a mold so that the male engaging element (a2) is on the bottom side of the recess, and in this state a molten liquid of a non-foaming resin satisfying the following condition iii) is poured into the mold, and after cooling, it is removed from the mold. i) the male molded surface fastener (A) comprises a resin base plate (a1) and a plurality of male engaging elements (a2) rising from the surface of the base plate (a1) and arranged in a row on the base plate (a1); ii) the male engaging elements (a2) are bent midway in the same direction as the row direction of the male engaging elements, with their tips approaching the substrate (a1), and the male engaging elements (a2) are made of the same resin as the resin constituting the substrate (a1); iii) the resin constituting the non-foamed resin sheet (B) is a resin constituting the male molded surface fastener (A) or a resin mainly composed of an elastomer resin of the same type as the elastomer resin constituting the male molded surface fastener (A), and the non-foamed resin has a lower hardness than the resin constituting the male molded surface fastener (A); The type D durometer hardness of the resin constituting the male molded surface fastener (A) is in the range of 50 to 100 in accordance with JIS K7215, and the same hardness of the resin constituting the non-foamed resin sheet (B) is in the range of 10 to 70, and the difference in hardness between the two is in the range of 20 to 60.

8. A method for producing a sheet with a male molded surface fastener according to claim 7, wherein the resin constituting the male molded surface fastener (A) satisfies the following iv) and the non-foaming resin satisfies any of the following v) to vii). iv) The resin constituting the male molded surface fastener (A) is a resin mainly composed of any one of polypropylene resin, polyester elastomer resin, and polyamide resin; v) When the resin constituting the male molded surface fastener (A) is a resin mainly composed of polypropylene resin, the non-foaming resin is a resin mainly composed of olefin-based elastomer resin; vi) When the resin constituting the male molded surface fastener (A) is a resin mainly composed of a polyester-based elastomer resin, the non-foaming resin is a resin mainly composed of a polyester-based elastomer resin; vii) When the resin constituting the male molded surface fastener (A) is a resin mainly composed of a polyamide resin, the non-foaming resin is a resin mainly composed of a polyamide elastomer resin;

9. A method for producing a sheet with a male molded hook-and-loop fastener having a non-foaming resin sheet (B) on the back surface of a male molded hook-and-loop fastener (A), the method comprising: pouring a molten resin that satisfies the following condition III) onto the surface of a metal roll that satisfies the following conditions I) and II) while forcing the molten resin into a cavity; further, superimposing and pressing a sheet (B) made of a non-foaming resin that satisfies the following condition III) onto the surface of the molten resin on the metal roll; cooling and solidifying the molten resin in this state; and then peeling it off from the surface of the metal roll and pulling it out of the cavity. I) The metal roll is formed by stacking thin ring-shaped dies each having a plurality of male engaging element-shaped notches carved on its outer circumference; II) A plurality of cavities for male engaging elements based on the cuts are arranged in a row in the circumferential direction of the metal roll on the surface of the metal roll, and each cavity is bent in the row direction of the cavities midway, with its tip end approaching the surface of the metal roll; III) The non-foaming resin is a resin mainly composed of an elastomer resin of the same type as the resin constituting the molten liquid or the elastomer resin constituting the male molded surface fastener (A), and the non-foaming resin has a lower hardness than the resin constituting the molten liquid; The type D durometer hardness of the resin constituting the male molded surface fastener (A) is in the range of 50 to 100 in accordance with JIS K7215, and the same hardness of the resin constituting the non-foamed resin sheet (B) is in the range of 10 to 70, and the difference in hardness between the two is in the range of 20 to 60.

10. The method for producing a sheet with a male molded surface fastener according to claim 9, wherein the resin constituting the molten liquid satisfies the following IV) and the non-foaming resin satisfies any of the following V) to VII). IV) The resin constituting the molten liquid is a resin mainly composed of any one of polypropylene resin, polyester elastomer resin, and polyamide resin; V) When the resin constituting the molten liquid is a resin mainly composed of polypropylene resin, the non-foaming resin is a resin mainly composed of olefin-based elastomer resin; VI) When the resin constituting the molten liquid is a resin mainly composed of a polyester-based elastomer resin, the non-foaming resin is a resin mainly composed of a polyester-based elastomer resin; VII) When the resin constituting the molten liquid is a resin mainly composed of a polyamide resin, the non-foaming resin is a resin mainly composed of a polyamide-based elastomer resin;

11. A method for producing a sheet with a male molded hook-and-loop fastener, having a non-foaming resin sheet (B) on the back surface of a male molded hook-and-loop fastener (A) that satisfies the following conditions i) to iii), by superimposing and pressing a molten sheet (B) made of a non-foaming resin that satisfies the following condition iii) on the back surface of the male molded hook-and-loop fastener (A), and then cooling and solidifying the sheet. i) the male molded surface fastener (A) comprises a resin base plate (a1) and a plurality of male engaging elements (a2) rising from the surface of the base plate (a1) and arranged in a row on the base plate (a1); ii) the male engaging elements (a2) are bent midway in the same direction as the row direction of the male engaging elements, with their tips approaching the substrate (a1), and the male engaging elements (a2) are made of the same resin as the resin constituting the substrate (a1); iii) the resin constituting the non-foamed resin sheet (B) is a resin constituting the male molded surface fastener (A) or a resin mainly composed of an elastomer resin of the same type as the elastomer resin constituting the male molded surface fastener (A), and the non-foamed resin has a lower hardness than the resin constituting the male molded surface fastener (A); The type D durometer hardness of the resin constituting the male molded surface fastener (A) is in the range of 50 to 100 in accordance with JIS K7215, and the same hardness of the resin constituting the non-foamed resin sheet (B) is in the range of 10 to 70, and the difference in hardness between the two is in the range of 20 to 60.

12. A method for producing a sheet with a male molded surface fastener according to claim 11, wherein the resin constituting the male molded surface fastener (A) satisfies the following iv) and the non-foaming resin satisfies any of the following v) to vii). iv) The resin constituting the male molded surface fastener (A) is a resin mainly composed of any one of polypropylene resin, polyester elastomer resin, and polyamide resin; v) When the resin constituting the male molded surface fastener (A) is a resin mainly composed of polypropylene resin, the non-foaming resin is a resin mainly composed of olefin-based elastomer resin; vi) When the resin constituting the male molded surface fastener (A) is a resin mainly composed of a polyester-based elastomer resin, the non-foaming resin is a resin mainly composed of a polyester-based elastomer resin; vii) When the resin constituting the male molded surface fastener (A) is a resin mainly composed of a polyamide resin, the non-foaming resin is a resin mainly composed of a polyamide elastomer resin;

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