Touch fasteners and methods of formation

Abstract

Aspects disclosed herein relate to forming on a substrate fastener elements suitable for use in touch fastener by employing vibration forming methods. The processes described provide for a greater flexibility in manufacturing than prior methods and overcome certain limitations in prior forming techniques. Further, the product made can embody a variety of different configurations suitable for a given application. Employing vibration forming methods, such as ultrasonic forming methods, allows for the use of a wider variety of substrate material than materials used with convention methods of touch fastener formation.

1 . A method of ultrasonically forming a touch fastener, the method comprising:
 heating the substrate from a first temperature to a second temperature below a melting point of the substrate; and   thereafter ultrasonically forming fastening elements on the substrate.   
     
     
         2 . The method of  claim 1 , wherein the second temperature is between or equal to about 30° C. and 100° C. 
     
     
         3 . The method of  claim 1 , wherein the substrate comprises a diaper tab. 
     
     
         4 . A touch fastener produced by the method of  claim 1 . 
     
     
         5 . A diaper tab produced by the method of  claim 1 . 
     
     
         6 . The method of  claim 1 , wherein the substrate comprises at least one of a loop material, a nonwoven material, and a foam. 
     
     
         7 . The method of  claim 1 , further comprising positioning the substrate adjacent a mold. 
     
     
         8 . The method of  claim 7 , further comprising applying energy to the substrate using a plurality of contact regions of the mold to soften at least a portion of the substrate. 
     
     
         9 . The method of  claim 8 , further comprising forcing the softened substrate material into one or more cavities formed in the plurality of contact regions to form a plurality of the fastening elements. 
     
     
         10 . The method of  claim 9 , further comprising forming a plurality of spaced-apart fields having a plurality of leading and trailing edges formed on a surface of the substrate, wherein each of the plurality of fields includes a plurality of the fastening elements. 
     
     
         11 . The method of  claim 1 , wherein the substrate is a preformed loop substrate material, and further comprising positioning the preformed loop substrate material adjacent a vibration source. 
     
     
         12 . The method of  claim 11 , further comprising forcing a portion of the preformed loop substrate material into one or more mold cavities upon vibration from the vibration source to produce the fastening elements.