METHOD FOR MANUFACTURING A REFASTENABLE MECHANICAL FASTENING SYSTEM HAVING AZIMUTHALLY ANGLED PRONGS AND FASTENING SYSTEM PRODUCED THEREFROM

METHODE DE FABRICATION D'UN SYSTEME DE FERMETURE MECANIQUE REUTILISABLE A CROCHETS INCLINES ET SYSTEME DE FERMETURE CORRESPONDANT

English Abstract

The invention is a refastenable mechanical fastening system (20), made of free formed prongs (22) joined to a substrate (24). The
prongs (22) taper and are nonperpendicularly oriented relative to the plane of the substrate (24). The prongs (22) also have an azimuthal
angle relative to the machine direction of the substrate. Each prong has an engaging means (30) projecting laterally from the periphery of
the prong (22). The free formed prongs are manufactured by the process of depositing liquid material onto a moving substrate to form the
base of the prong, stretching the liquid material in a direction parallel to the plane of the substrate, severing the stretched material to form
the distal end and engaging means of the prong and allowing the prong to azimuthally angle. The advantageous usage of the fastening
system in an article of manufacture, such as a disposable absorbent article specifically a diaper, is also disclosed.

French Abstract

L'invention consiste en un système (20) d'attache mécanique réattachable, constitué de crochets (22) formés libres, joints à un substrat (24). Lesdits crochets (22) sont coniques et orientés de manière non perpendiculaire par rapport au plan du substrat (24). Les crochets (22) présentent également un angle azimutal par rapport au sens de production du substrat. Chaque crochet (22) présente un moyen (30) de prise saillant latéralement de sa périphérie. Le procédé de production des crochets formés libres consiste à déposer une matière liquide sur un substrat mobile afin de former la base du crochet, à étirer la matière liquide dans une direction parallèle au plan du substrat, à détacher la matière étirée afin de former l'extrémité distale et le moyen de prise du crochet, et à laisser ledit crochet former un angle azimutal. L'invention concerne également l'utilisation avantageuse du système d'attache applicable à un article manufacturé tel qu'un article absorbant disposable, spécifiquement une couche.

Claims

58
What is Claimed:
1. A method for manufacturing one or more azimuthally angled prongs useful as
a component of a fastening system. characterized in that the method
comprises the steps of:

providing a depositing member having at least one cell, said cell having a
major axis and a minor axis, either said minor axis being oriented in a
direction other than the machine direction of said depositing member or said
cell has a dominant area on one side of the machine direction centerline;

providing a molten thermally sensitive material;

providing a substrate;

depositing a discrete amount of said molten thermally sensitive material from
said cell onto said substrate;

stretching a portion of said discrete amount of said molten thermally sensitive
material in a direction having a vector component parallel to the plane of said
substrate so as to form a prong, said prong comprising a footprint, a base, a
shank, and an engaging means, said footprint having either a major axis and a
minor axis, corresponding generally to said major axis and said minor axis of
the said cell or a dominant area on one side of the machine direction
centerline;

solidifying said molten thermally sensitive material of said prong so as to forma maximum lateral projection, said maximum lateral projection being oriented
either in a direction other than the direction of said major axis of said
footprint or generally toward said dominant area of said footprint, such that
said prong is azimuthally angled.

2. The method of Claim 1 additionally comprising the steps of transporting said
substrate in the machine direction.

The method of Claims I or 2 wherein at least one cell has an aspect ratio
greater than 1.5:1, preferably greater than 2:1, and more preferably greater
than 3 :1.

59

4. The method of Claim 3 wherein at least one cell has a substantially
rectangular, elliptical or triangular sectional area.

5. The method of Claim 4 wherein at least one cell as a triangular sectional area
comprising a first side and a second side which are equal in length, and a thirdside which is longer than said first side and said second side and is generally
parallel to the machine direction of said depositing member.

6. A method for manufacturing a fastening material have one or more
azimuthally angled prongs, characterized in that the method comprises the
steps of:

providing a depositing member having at least one cell, said cell having a
bottom surface comprising a first portion and a second portion, the depth of
said first portion being greater than the depth of said second portion, said first
portion being oriented relative to said second portion in a direction other thanthe machine direction;

providing a molten thermally sensitive material associated with said
depositing member;
providing a substrate;

depositing a discrete amount of said molten thermally sensitive material onto
said substrate;

stretching a portion of said discrete amount of said molten thermally sensitive
material in a direction having a vector component parallel to the plane of said
substrate so as to form a prong, said prong comprising a footprint, a base, a
shank, and an engaging means, said footprint having a first portion and a
second portion corresponding generally to said first portion and said second
portion of said cell; and

solidifying said molten thermally sensitive material of said prong so as to forma maximum lateral projection, said maximum lateral projection being oriented


away from said second portion of said footprint such that said prong is
azimuthally angled.

7. The method of Claim 6 wherein the ratio of the depth of said first area of said
cell to the depth of said second area of said cell is at least 1.1:1, preferably at
least 2: 1.

8. The method according to any of the preceding claims additionally comprising
the step of biasing said prongs prior to solidifying said molten thermally
sensitive material to assist in orienting said prongs.

9. A fastening material for attaching to a complimentary receiving surface, said fastening material manufactured according to the method of any of the
preceding claims.

10. An absorbent article comprising:

an outer cover comprising:

a topsheet; and

a backsheet joined with said topsheet;

an absorbent core positioned between said topsheet and said backsheet; and

a fastening material according to Claim 9 joined to said outer cover,
preferably to said backsheet.

Description

-

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2 1 6333 t



METHOD FOR MANUFACTURING A REFAS~ENABLE MECHANICAL
~AS~ENING SYSTEM HAVING A~IMU~HALLY ANGLED PRONGS
AND FAS~ENING SYS~EH PRODUC~D THEREFROM




FIE-D OF THE INVENTION
~he present ~nvent~on relates to refastenable mechanical
fastening systems hav~ng a~imuthally anglet free formed prongs
and the process of manufacturtng such fastening systems.
BACKGROUND OF THE INVENTION
Refastenable ~echanical fastening systems are well known in
the art. T~pically such fastening systems involve two ma~or
components a prong whiCh i s ~oinea to a substrate and engages
with a complementary second component the receiving surface. A
projection of the prong of the fastening system penetrates the
receivinS surface ~nd either engages or ~ntercepts strands or
fibers of the rece~v~ng surface. ~he resutt~ng mechan k al
interference and physical obstruction prevent removal of the
fastening system from the receiving surface unt~l the separat~on
forces exceed either the peel or shear strength of the fasten~ng
system.
Presently refastenable mechanical fastening systems are made
by at least two general methods. One method requires a plurality
of filaments each of which may be formed ~nto two prongs.

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~xamples of fasten~ng systems produced by this method are shown ln
U.S. Patent No. 2 717 ~37 ~ssued September 13 1955 to de
Hesteral and U.S. Patent No. 3 943 981 issued March 16 1976 to
De Brabandar ~hich teach a raised pile of loops. Related
teachings are shown ln U.S. Patent No. ~ 216 257 issued August 5
1980 to Schams et al. U.S. Patent No. ~ 45~ 183 ~ssuet June 12
1984 to ~oll~an and U.S. Patent No. ~ 463 486 issued August 7
198~ to ~atsuda. ~hese references teach heating the ends of
polymeric monofllaments. Other related teach~ngs of fastentng
systems produced by the first nethod are disclosed ln U.S. Patent
No. ~ 307 ~93 issued December 29 1981 to Och~ai and U.S. Patent
No. 4 330 907 issued May 25 1982 to Ochi~1.
The second general method commonly utilized to manufacture
mechanical f~stening systems is to mold or extrude the systems as
illustrated ln U.S. Patent No. 3 1~7 528 ~ssued September 8 196
to Erb and U.S. Patent Ho. 3 59~ 863 issued July 27 1971 to Erb.
Cont~nuous injection molding ls taught in U.S. Patent No.
3 59~ 865 lssued July 2~ 1971 to Erb.
Yarious prong structures are lllustrated in the prior art.
For example the references disc~ssed above teach fasten~ng
systems hav~ng stems of generally const~nt cross section. U.S.
Patent No. 3 708 833 ~ssued January 9 1973 to Rib~ch et al.
discloses a prong which is somewhat tapered from the proximal end
to the distal end ~nd perpendicularly pro~ects from the substrate.
Europe~n Patent Appl k at~on No. 0 276 970 publ~shet January
26 1988 by the Procter ~ 6a~blc Company in the name of Scripps
discloses a fastening dev~ce hav~ng a constant cross section sten
or~ente~d ~t ~n angle between about 30- and about 90- rel~tive to
the base.
Fastenlng systems having free formed prongs generally are
produced with all the prongs oriented in one directlon i.e. the
machine d~rection of the substrate. ~here is however a need for
fastening systems having free formed prongs wherein the prongs are
oriented in a direction other than the machine direction. For
example ~hen a fastening system hav1ng free formed prongs is used
as the fastening means of a disposable diaper a fastening system
with prongs oriented ln the cross-machine direction of the

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substrate can more easlly be applled to the diaper on a high speed
diaper manufacturing llne than can a fastenlng system wlth prongs
orlented ln the machlne directlon of the substrate. There is also
a need for fastening systems having free formed prongs whereln the
prongs are orlented in several directlons. for example
fastening system having prongs or~ented in several dlrections wlll
have a more isotropic peel strength than a fastening system havlng
all the prongs oriented ln one dlrection.
These needs have been addressed ln U.S. Patent Appllcatlon
07/632 283 flled December 21 1990 ln the name of Dennls A.
Thomas David J. K. Goulalt and Robert G. Cox Jr. entltled
^Refastenable ~echanical F-stenlng System and Process of
Man~facture ~herefor~ which dlsclosed a method of manufacturing a
fastening system having free formed prongs whlch are externally
biased or forced to orient ~n a dlrection other than the machlne
dlrection of the substrate. However this method tends to ortent
substantlally all or a large number of prongs in the sa~e
directlon or orlent the prongs ln several dlfferent dlrectlons by
uncontrolled scatterlng- of the prongs.
It ~s therefore an ob~ect of the present lnventlon to
disclose a ~ethod of produclng azimuthally angled prongs.
It ls also an object of the present lnventlon to disclose a
~ethod for produclng a fastenlng system havlng prongs by whlch the
general directlon of orientatton of e-ch indlv1dual prong can
substantlally be controlled or manlpulated.
It ls also an object of the present lnvent10n to dlsclose a
method for produclng a fastenlng system havlng prongs ln whlch
each prong of the fasten~ng system ls oriented ln a predetermlned
directlon.
It ls also an object of the present inventlon to disclose a
fastening system havlng prongs ln whlch each prong of the
fastening system is orlented in a predetermined direction.
BRIEF SUMMARY OF THE INVENTION
The present invention relates to a fastening system for
attaching to a complementary receiving surface and the fastening
system produced therefrom. The fastening system has a substrate
and at least one free formed prong comprising a base shank and

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engaging means. The base of the prong is ~oined to the substrate
and the shank is contiguous with and pro~ects outwardly from the
base. The engaging ~eans is ~oined to the shank and projects
laterally be~ond the periphery of the shank. The shank is
nonperpendicularl~ or1ented relative to the pl~ne of the
substrate. The sh~nk has a leading edge ~nd a trailing edge
defining a leading angle ~nd trailinq angle respectively. The
leading angle and trailing angle are substantial~y different fro~
each other so that the s~des ûf the shank ~re nonp~rallel. The
shank also has an az~muthal ~ngle. The azimuthal angle can be
between aboùt l- and about I80- preferably between about 20- to
about I60- relative to the machine d~rect10n.
The f.stening system ma~ be made according to the process
comprising the steps of heat1ng a thermally sensitive ~aterlal
suffkiently to reduce 1ts v~scosity for processing and
preferably to at least lts melting po~nt. A deposit1ng member for
depositing discrete amounts of the heated material such ~s
hot-melt adhesive thenmoplast1c is prov~ded. The substrate to
~hich the materi~l ls to be ~oined is transported ~n a first
d1rection relative to the deposittng member. The mater~al is
deposited on the t nnsported substrate in discrete amounts. The
discrete amounts of ~ater1al ~re then stretched in a direction
having a vector component generally p~rallel to the plane of the
substrate. The stretched ~aterial is severed to for~ ~ distal end
and engagtng means ~nd the d~st~l end and eng-g~ng ~e~ns will
fonm an a~inuth~l ~ngle between about 1- to about l80-, preferably
between about 20 to about l60- 1s inparted to the shank.
An lllustrattve ~nd suitable but nonlim1ting use for the
fastenlng syste~ produced by the process of the present invention
is in con~unction with a dlsposable absorbent art1cle such as a
diaper. This example of one usage of the fastening system of the
present invention is more fully described below.
BRIEF OESCRIPTlON OF THE ORAWINGS
While the Specification concludes with claims particularly
pointing out and distinctly claiming the invention it is believed
the invention will be better understood from the following
description taken in conjunction with the associated drawings in

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5

wh1ch like elements are described by the same reference numeral
and related elements ~re des19nated by adding one or more prime
symbols or 1ncrement1ng the numeral by lO0:
Figùre l ts a photomicrograph showing ~ perspective view of ~
fastening system wherein the engaging means are oriented in
substantlally the same d1rectlon;
Fllgure 2 1s ~ side elevational view of one prong of the fastentng
system sho~n 1n Figure l; s
F1gure 3 1s ~ s1de elevat10nal v1ew of a second embod1~ent having
a gener~lly sem1spher1cally shaped engag1ng means;
Flgure ~ ts a s1de elevat10nal schemat1c view of one apparatus
wh1ch can be used to produce the fasten1ng system of the
presen~ invention;
Figure S is a photomicrograph showing a perspective v1ew of a
fastening system where1n the engaging ~eans are oriented 1n
substanti~ random direct1cns;
Figure 6 is ~ perspect1ve v1ew of a disposable absorbent garment
ut111zing the fasten1ng syste~ of the present 1nvent10n
showing the topsheet and core part1ally cut-away;
Figure 7 ~s a top plan v1ew of one prong having an azlmuthal angle
of about 90-;
F19ure 8 1s a front elevat10nal v1e~ of one apparatus (only a
port10n of which 1s shown) which can be used to produce the
fastcn1ng system of the present invention hav1ng az1muthally
angled prongs;
Fiqure 9 1s a top plan v1ew of ~ second apparatus wh1ch can be
used to produce the fasten1ng systea of the present 1nvent10n
hav1ng az1muthally angled prongs.
Figure lO 1s a top plan v1ew of one cell having major axes and
m1nor ~xes which can produce azimuthally angled prongs;
Figure 11 is a top plan view of a cell having a major axis and
minor axis which can produce azimuthally angled prongs;
Figure 12 is a top plan view of another cell having a major axis
and minor axis which can produce azimuthally angled prongs;
Figure 13 is a top plan view of a cell having a major axis and
minor axis;
ligure l~a is a top plan v1ew of a closed-end cell having a

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circular section~l are~ at the surface of the print roll;
Figure 14b is a cross-sectional vie~ of the cell of F1gure 14a;
~igure 15a is a top pl~n view of a closed-end cell havlng two
bottom surface portions of unequal depth;
~igure 15b is a cross-sectional view of the cell of Figure ISa;
Figure 16 ~s a photo icrograph showlng a top plan view of ~
fastening syste of the present invention ~herein the prongs
were produced from cells similar to the cel~ shown ~n F~gure
I2 and engaging ~eans are orientet in substantially the same
directton; and
Figure 17 is a photo icrograph showing ~ top plan vie~ of a
fasten~ng syste- of the present ~nventlon wherein the prongs
were produced from cells sim~lar to the cell shown in Figure
Il and engaging oeans are or1ented ~n substant~ally the samæ
direction.
DETAILED DESCRIPTION OF THE INVEH~ON
The fasten1ng s~stem 20 of the present invention comprises at
least one prong 22 having an a2imuthal ngle and preferably ~n
array of such prongs 22 ~oined to a substrate 2~ ~n
predetermined pattern as shown tn Fi~ures 16 and 17. Though ~t
should be understooJ that because the general orientation of each
individual prong can substantially be controlled the prongs 22 of
the ~rray need not be oriented in the same direction and ~ay be
oriented in man~ different directions. The array ~ay consist of
az~mut~ally anglet prongs be~ng pos~t10ned ad~cent to
non-azimuthally angled prongs or prongs hav1ng ~ different
~z~muthal anglc. It should there h re, be understood that the
prongs 22 of the array ~ay be arranged in an unl~m~ted number of
possible patterns.
A prong 22 has a base 26~ shank 28 and engaging means 30.
The bases 26 of the prongs 22 contact and adhere to the substrate
24 and support the proximal ends of the shanks 28. The shanks 28
project outwardly from the substrate 24 and bases 26. The shanks
28 terminate at a distal end 29 which is joined to an engaging
means 30. The engaging means 30 project laterally from the shanks
28 in one or more directions and may resemble a hook-shaped tine.
As used herein the term lateral~ means having a vector component

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generally parallel to the plane of the substrate 24 ~t the
principal prong 22 under cons1derat10n. The pro~ectlon of an
engaging means 30 from the shank 28 periphery 1n a lateral
direction allows the engag1ng means 30 to be secured to
complementary receiving surface (not shown). The engag1ng means
30 is ~o1ned to and preferably cont1guous w1th the d1stal end 29
of the shank 28.
The array of prongs 22 may be produced by an~ su1t~ble method
wllich yields a free formed prong 22. As used here~n the ter~
~free formed~ means a structure wh1ch 1s not removed fro~ a mold
cavity or extrusion die ~n sol~d form or w~th ~ defined shape.
The prongs 22 are deposited onto a substrate 24 ln a 001ten
preferably liquid state and solidify by cooling unt~l rigid and
preferably freezing into the des1red structure ~nd shape ~s
descr~bed here1nafter.
The free formed array of prongs 22 is preferably produced by
a manufacturing process described hereinbelow which ~s s1m~1ar to
that process commonly known as gravure printlng. The free formed
array of prongs 22 may also be produced by a manufacturing process
which ~s slm11ar to that process commonly known as scree~ pr1nt1ng
or micro-screen printing wh1ch 1s more preferred 1f a denser
array of prongs 22 is des1ret. A screen pr1nt1ng process 1s
described in our commonly assigned co-pend1ng U.S. Patent
Application; Procter and Gamble Case f~4l8; Denn1s A. Thomas and
Dav1d J.K. 60ula1t; ~Screen Pr1nt1ng Hethod for ~anufactur1ng ~
Refastenable Hechan1cal Fasten1ng System And ~astenlng System
Produced ~herefrom~ flled concurrently herewtth; the
spec1flcat10n ~nd draw1ngs of whlch ~re 1nco~porated here1n by
reference. Other methods of produclng free for~ed prongs 22 wlll
be apparent to one skilled 1n the art. However for ease of
description only that process which is similar to the gravure
printing process will be illustrated herein.
Using the manufacturing process which is similar to that
process commonly known as gravure printing a substrate 24 having
opposed faces is passed between the nip 70 of two generally
cylindr1cal rolls a print roll 72 and a backing roll 74 as
illustrated at Figure 4. The rolls 72 and 74 haYe generally

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parallel centerlines and are maintained in contacting relationsh1p
with the substrate 2~ as it passes through the nip 70 One of the
rolls referred to as the print roll 72 has an arr-y of blind
closed-end cavities referred to as cells 76 correspond1ng to the
desired pattern of prongs 22 to be depos~ted on the substrate 2
The second roll referred to as the backing roll 7~ provides the
reaction against the print roll 72 to pos~tion the substrate 2
against the print roll 72 as the substrate 2~ passes through the
nip 70 Liquid then~ally sensit1ve materlal preferably
thermoplastic material from which the prongs 22 are to ~e formed
is supp~ied from a heated source such as a trough 80 The
thermall~ sensitive material is lntroduced into the cells 76 as
the print roll 72 is rot-ted about its centerl1ne The cells 76
cont~ning the thermally sensitive materlal transport it until
contact with the substrate 2~ is made and depos1t th1s ~aterial
onto the substrate 2~ in the des1red pattern.
As relative displ-cement between the substrate 2~ and rolls
72 and 7~ increases the prongs 22 are stretched ~n a direction
hav1ng a lateral vector co~ponent generally parallel to the plane
of the substrat~ 2~ fornlng the shank 28 and the engaging ~eans
Fin~lly the moil of the prong 22 is severed from the
engaging ~eans 30 by a severing neans 78 Due to the v~scoelast k
propert~es of the ther~opl~stic the prong 22 contracts It is
also belleved that the prong 22 retr~cts under the ~nfluences of
grav1ty ~nd shr~nk-ge wh~ch occur dur~ng cool1ng The prong 22
then cools and preferably freezes lnto a sotld structure h~vtng
the engaging reans 30 contiguous ~ith the shank 28
The fastening systee 20 1s secured to a comple~entary
receiving surface. As used herein the tenm ~receiving surf~ce~
to which the engaging means 30 of the fasten~ng s~ste~ 20 are
secured refers to any plane or surface having an exposed face with
tightly spaced openings complementary to the engaging means 30 and
defined by one or more strands or fibers or alternatively which
exposed face is capable of localized elastic deformation so that
the engaging means 30 may become entrapped and not withdrawn
without interference The openings or localized elastic
deformations allow for entry of the engaging means 30 into the

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~ 21 63331




plane of the receivlng surface while the strands (or nondeformed
~aterial) of the receiving surface 1nterposed between the openings
(or deformed areas) prevent withdrawal or release of the fastening
system 20 until desired by the user or e~ther the peel or shear
strength of the fastening system 20 is otherwise exceeded. ~he
plane of the receiving surface nay be flat or curved.
A receiv~ng surface having strands or fibers is said to be
complementary- 1f the openings between strands or fibers are
sized to ~llow at least one engaging ~eans 30 to penetrate into
the plane of the receiving surface and the strands are si~ed to
b~e engaged or tntercepted by the engaging ~eans 30. ~ receiving
surface which ls locally deformable is said to be co~plementary-
if at least one engaging means 30 is able to cause a localized
disturbance to the plane of the rece~ving surface which
disturbance reststs removal or separat1On of the fastening system
20 from the receiving surface.
Suitable receiving surfaces include reticulated foams
knitted fabr~cs woven naterials nonwoven materials and
stitchbonded loop mater1als such as Velcro brand loop materials
sold by Velcro USA of Hanchester New Hampsh~re. A partlcularly
suitable rece~v~ng surface ts stitchbonded fabric Humber 9~0026
sold by the Milliken Company of Spartanburg South ~arolina. If a
cense array of prongs 22 is being used another particularly
suitable recelv~ng surface is a polypropylene non-woven fabric
having a basls we1ght of about 17.1 grams per square ~eter (0.5
ounces per square yard) m-de by any suitable commerc~al carding or
spunbonding processes. Suitable non-woven fabrics can be obtained
from Veratech Hon.l~ven Group of the International Paper Company of
~alpole Massachusetts 02081. As used herein the ter
~dense array of prongs~ refers to an array of prongs having from
about 64 to about 1600 prongs per square centimeter (400 to lO 000
prongs per square inch) of substrate 24.
Referring back to Figure 2 to examine the components of the
fastening system 20 in more detail the substrate 24 of the
fastening system 20 should be strong enough to preclude tearing
and separation between individual prongs 22 of the fastening
system 20 be a surface to which the prongs 22 will readily adhere

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2 1 6333 1 ~


and be capable of being ~oined to an ~rticle to be secured as
desired by a user. As used herein the term ~oin- refers to the
condltion where a first member or component is affixed or
connected to a second member or component either d~rectly; or
indirectly where the first ~ember or component is affixed or
connected to an intermed~ate member or component ~h kh in turn is
afflxed or connected to the second member or component. The
association between the f~rst member or component and the second
member or component ls intended to remain for the 11fe of the
art1cle. ~he ~substrate~ is any exposed surface to ~h~ch one or
more prongs 22 are ~o~ned.
The substrate 24 should also be capable of being rolled to
support conventional manufacturing processes flexible so that the
substrate 24 ~ay be bent or flexed in a des~red conf~guration and
able to wlthstand the heat of the ltquid prongs 22 being deposited
thereon ~ithout melting or incurring deleter~ous effects untl1
such prongs 22 free~e. However if the substrate 2~ is a material
wh~ch ~s senslt~ve to heat then a ch~lled roll ay be used as a
backing roll 7~ to enable such materials to be used as the
substrate. The substrate 24 should also be available ~n a variety
of widths. Suitable substrates 24 include knltted fabric woven
materials nonwoven materials rubber vinyl fll~s particul~rly
polyolefinic f~lms and prefer~bly kraft paper. ~hite kraft paper
having a basis weight of 0.08 k~logr~ms per square meter (50
pounds per 3 000 square feet) has been found suitable. A
polyester film substrate 24 havlng a basis weight of 17.1 grams
per square ~eter (1~.26 grams per square y~rd) and a thickness of
about 0.008 to about O.lS ~illimeters (0.000 to 0.006 inches) has
also been found suitable.
The base 26 is the generally planar portlon of the prong 22
which is attached to the substrate 24 and is contiguous with the
proximal end of the shank 28 of the prong. As used herein the
term ~base~ refers to that portion of the prong 22 which is in
direct contact with the substrate 24 and supports the shank 28 of
the prong 22. It ~s not necessary that a demarcation be apparent
between the base 26 and the shank 28. It is only important that
the shank 28 not separate from the base 26 and that the base 26

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not separate from the substrate 24 during use The base 26 cross
sect)on should provide sufficient structural )ntegrlty and hence
area for the desired peel and shear strengths of the fastening
system 20 based on the density of the pattern of prongs 22 and
length of the shanks 28 of the individual prongs 22 and further
prov)de adequate adhesion to the substrate 24 If a longer shank
28 )s ut11)~ed the base 26 should gener~lly be of greater cross
xectional area to provide sufficient ~dhesion to the substrate 2
and adequate structur~l ~ntegrlty
~ he shape of the footprint of the base 26 on the substrate 24
generally corresponds to the shape of the cell s sect10nal area at
~he surface of the print roll 72 As used here1n the ter~
~footpr)nt~ refers to the planar contact area of the base 26 on
the substrate 2~ As the aspect ratio of the sides of the
footprint increases the prong 22 ~ay become unstable when
subjected to forces such as gravitat)onal forces parallel to the
shorter dimens10n of the footprint To produce a prong 22 which
)s not az)muth~lly angled n spect rat)o of less than about
1 5:1 ~s preferred and ~ gener-lly circul~r footpr~nt ~s more
preferred However to produce ~zimuthally angled prongs 22
according to the method of the present invention n aspect ratio
greater than about 1 5 1 )s preferred and a generally e11)ptical
or triangular footprint hav)ng an aspect ratio greater than about
1 5 1 ~s even more preferred Methods of produc1ng az)muthally
angled prongs wlll be dtscussed )n greater detall here1nbelow
~ he shank 28 ~s contiguous wlth the base 26 and projects
outwardly from the base 26 ~nd substr~te 24 As used herein the
tera ~shank~ refers to that portlon of the prong 22 wh~ch is
)ntermed)ate of and contiguous w)th the base 26 and the engag)ng
means 30 The shank 28 prov)des longitud~nal spac)ng of the
engaging means 30 from the substrate 24 As used herein the term
~longitudinal~ means ~n a direct)on having a vector component away
from the substrate 24 which direction increases the perpendicular
distance to the plane of the substrate 24 at the base 26 of the
prong 22 unless otherw)se specified to be a direct)on having a
vector component towards such plane of the substrate 24

WO 94127461 PCT/US94/05115
2 1 6333 1 ~


Associated w~th the shank 28 nd base 26 of each prong 22 is
an origin 36 The ~origin~ of the shank 28 is the point ~hich may
be thought of as the center of the base 26 and is typically
within the footprint of the base 26 ~he orig~n 36 ~s found by
viewing the prong 22 from the side view The ~side view~ is any
direction radlally tow-rds the shank 28 and b~se 26 wh~ch is also
parallel to the plane of the substrate 2~
The l-teral distance between the remote edges of the base 26
footprint h r the particular side view under constderat~on is
found and this distance 1s bisected yielding the midpoint of the
base 26 for such view ~hen bisecting the footprint of the base
26 for the part k ular slde v~e~ under consider~tlon m~nor
discontinuities (such as fillets or asperities incident to the
attac~ ont to substrate 24) are ~gnored This po~nt ~s the origin
36 of the shank 28
The shank 28 makes an angle o with the plane of the substrate
2~ As used herein the term plane of the substrate- refers to
the flat pl-nar surface of the substrate 2~ at the base 26 of the
principal prong 22 under considerat1On The angle ~ ls determined
as follo~s ~he prong 22 1s vie~ed 1n profile The profile
view- of the prong 22 ~s one of two particular side views and
found as follows ~he prong 22 is visually inspected from the
side v~ews such that the d1rection having the 0axi~um lateral
project~on 3a becomes apparent ~he l-teral pro~ect1On- is the
d~stance taken later~ nd parallel to the plane of the
substr-te 24 from the center of the base 26 ln such v~ew, ~ e the
or~gin 36 of the shank 28 to the projection of the furthest
laterally remote point on the prong 22 vts~ble 1n such v~e~ when
such point is longitudinally and perpendicularly projected
downward to the ptane of the substrate 24
It will be apparent to one skilled in the art that the
maximum laterat projection 38 is that projection from the origin
36 to the outer periphery of the shank 28 or engaging means 30
The side view of the prong 22 which maximizes the lateral
pro~ection 38 is the profile view of such prong 22 It will also
be apparent to one skilled in the art that if the fastening system
20 is produced by the process described and claimed below and if

WO 94/27461 PCT/US94/05115
~ 2 1 6333 1
13

the maxlmum lateral pro~ectlon 38 ls generally orlented ln the
machlne directlon then the profile vie~ w111 be generallr
oriented ln the cross-machlne directlon It will also be apparent
that lf the maxl~um lateral pro~ectlon 38 ls generally orlented ln
the cross-machlne directlon then the proflle vlew will be
generally oriented in the machlne dlrection The slde elevat10nal
view shown in Figure 2 is one of the profite vlews of the prong
22 It wlll be further apparent to one skllled in the art that
there 1s another profile vlew generally 180- opposlte from the
proflle vle~ shown (so that the ~aximum lateral pro~ectlon 38 is
orlented tow~rds the left of the viewerJ Elther of the two
profile views ls generally equally well sulted for the procedures
and usages descrlbed herelnbelo~
The origln 36 of the shank 28 ls found as descrlbed above
~ith the prong 22 ln the proflle vlew ~hlle stlll ma~ntalning
the prong 22 in the profile vlew an lmaglnary cutting plane
40-~0 generally parallel to the plane of the substrate 24 ls
then ~rought lnto tangency wlth the perlphery of the prong 22 at
the polnt or segment of the prong 22 havlng the greatest
perpendlcular tlstance from the pl-ne of the substr~te 24 Thls
corresponds to the portion of the prong 22 having the highest
elevation The imaginary cuttlng pline 40-40 is then brought
one-fourth of such greatest perpendicular distance closer to the
substrate 24 from the po~nt of hlghest elevatlon so that the
l~aglnary cuttlng plane 40-40 ~ntercepts the prong 22 at a
longltudln-l elev-tlon three-fourths of the perpend~cular dlstance
from the pl-ne of the substrate 2~
The l~aginar~ cutt1ng pl~ne ~0-~0 is then used to determine
three polnts on the prong 22 The flrst polnt ls that polnt where
the cuttlng plane lntercepts the leadlng edge 42 of the prong 22
and is referred to as the 75% leading point 44 The leading
edge~ is the apex of the periphery of the shank 28 which
longitudinally faces away from the plane of the substrate 24 The
second point ls disposed about 180 through the center of the
prong 22 and is the point where the cutting plane 40-40 lntercepts
the trailing edge 46 of the prong 22 and is referred to as the 75%
trailing point 48 The ~trailing edge- is the apex of the

WO 94t27461 2 1 6 3 3 3 1 PCT/US94/05115
.




1~

periphery of the shank 28 wh kh longitudin~lly faces towards the
substrate 2~ and is generally oppositely disposed from the lead~ng
edge 42. ~he straight line connecting these two polnts falls of
course ~ithin the cutting plane 40-~0 and is bisected to yield
the midpoint ~7 of the imag~nary cutting plane ~0-40. A straight
~ine is then dr~n connecting the midpoint 4~ of the imaglnary
cutting plane 40-~0 with the orlgln 36 of the shank 28 ~t the base
26. The included angle ~ this l~ne defines relatlve to the plane
of the substrate 24 is the angle ~ of the shank 28.
Alternatively stated the angle ~ which the shank 28 makes
relative to the plane of the substrate 24 is the 90- comp~ement of
that angle furthest from the perpendicular defined by the llne
found in any side view connecting the cutting plane midpoint ~7
and the origin 36. ~ence the smallest angle relative to the
plane of the substrate 2~ when this l~ne ~s vlewed 1n any
d~rectlon r~dially towarts the shank 28 and particularly the
origin 36 ~hich directlon ~s generally parallel to the plane of
the substrate 24 and orthogonal to the perpendicut~r ls the angle
of the sh~nk 28. It 1s to be recognized th-t when a prong 22
hav~ng a ~ax~u~ lateral pro~ect~on 38 or1ented in the nachlne
directlon 1s viewed appro%imatel~ in the machine direction or
approxi~tc1~ 180 therefrom or when ~ prong 22 hav~ng a oaximum
lateral project1On 38 or~ented 1n the cross-mach~ne direction ~s
viewed approximately ~n the cross-m~chine direction the apparent
angle ~ of the shank 28 ~tll be about 90-. 1lo~ev~ as dlscussed
above the angle ~ to be measured ~s that wh1ch deviates furthest
fro~ the perpendlcular and therefore ts gener~lly that angle ~
tetermlned when the prong 22 is viewed in prof~le typ1cally from
about the cross-machtne dlrection for a prong 22 or~ented ~n the
machine direction and from about the machine d1rection for a
prong 22 oriented in the cross-machine direction.
The angle ~ of the shank 28 may be generally perpendicular to
the plane of the substrate 24 or is preferably oriented in an
acute angular relation relative thereto to provide increased peel
strength in a particular direction, which direction is generally
parallel to the maximum longitudinal projection 38. However the
angle ~ of the shank 28 should not deviate excessively from the

WO 94/27461 2 1 6 3 3 3 1 PCT/US94/05115

15


perpendicular otherw1se a fastening system 20 of more
direct10nally specific shear strength results. For the embodiment
described hereln a shank 28 having an angle ~ between about 45-
and about 80- preferably about 65- works well. If the angle of
the shank 28 ls less than about 80- the shank 28 is considered to
be nonperpendicularly oriented relative to the plane of the
substrate 2~ (without regard to lateral orientation).
The 1maginary cutting plane ~0-~0 and profi~e vtew can also
be util ked to determine the angles of the lead~ng edge ~2 ~nd the
trailing edge ~6 relative to the plane of the substr~te 24. To
determine these angles the 75% leading point ~ and 75X tra~l1ng
point 48 are found as described above. The base leading point 50
is found as follows. The line through the base 26 ~s viewed 1n
profile is brought to intersect the leading edge ~2 of the shank
2~. Th1s intersection 1s the ~b-se leading po1nt. As noted
above m1nor discontinulties 1n the shank 28 near the base 26
incident to ~ttachment to the substr~te 2~ are not cons1dered
~hen detenmining the base leadlng point 50. The ~SX leading edge
point U is connected by a stra~ght line to the base leading edge
po1nt 50. Th1s straight 11ne fonms an 1ncluded angle ~L relat~ve
to the plane of the substrate 24 and opening in the direct10n of
the orlgin 36 nd center of the shank 28. ~he angle ~L 1s
referred to as the angle of the leading edge ~2 or simply the
leading edge angle.
The base tra11ing po1nt 52 is generally disposed 180- from
the base leading po~nt 50 through the center of the b~se 26 and
found as follows. The t1ne through the footprint of the base 26
as viewed in prof11e 1s brought to 1ntersect the tra111ng edge ~6
of the shank 28. This 1ntersect10n 1s the base trall1n~ po~nt.-
As noted above minor discontinuities in the shank 28 near the
base 26 incident to attachment to the substrate 24 are not
cnnsidered when determining the base trailing point 52. As
described above the 75% trailing point 48 is connected with the
base trailing point 52 by a straight line. This straight line
forms an included angle ~T relative to the plane of the substrate
24 and opening in the direction of the origin 36 and center of the

WO 94/27461 2 1 6 3 3 3 1 PCT/US94/05115

16

shank 28 The )ncluded angle ~T is referred to as the angle of
the traillng edge 46 or slmply the tralllng edge angle
The leadlng edge ~2 and trall1ng edge 46 included angles ~L
and ~T def~ne the parallelis- of the sides of the sh~n~ 28 If
the angles PL and ~ of the leading and trailing edges ~2 and 46
are not supplementary to each other (do not add to an arithmetic
sum of about 180 ) the sldes of the sh~nk 28 are s~id to be
nonparallel If the sides of the shank 28 are nonpar~llel the
straight tines wh~ch def1ne the angles ~L and OT (connect~ng the
base leadlng and trail~ng po)nts 50 and 52 wlth the 75X lead1ng
and trailing polnts U and 48 respectivel~) intersect either
above or below the plane of the substrate 2~ If the angles ~L
and ~T of the leadlng and trall)ng edges 42 and 46 are unequal and
the llnes defining such angles ~ntersect above the plane of the
substrate 2~ (longltudlnall~ outw~rdly of the base 26) the prong
22 wlll converge from the base 26 towards the dlstal end ~nd
engaging means 30 Onl~ )f the angles ~L and ~T of the lead)ng
~nd trailing edges 42 nd 46 have the s~e sense ) e are
orlented ln the same dlrect)on and supplementary ~agn)tudes are
the angles ~L ~nd ~T of the lead~ng and tra)ltng edges ~2 and ~6
determlned to be equal and the sides of the shank 28 to be
parallel
A shank 28 havlng a lead)ng edge 42 which forms a lead~ng
edge angle d~ w~th the substr-te of about 45 + 30- 1s su~table.
trall~ng edge ~6 wh)ch forns a tra~l~ng edge angle 0~ w~th the
substrate of about 65 + 30 ~s suitable A shank 28 havlng these
angles ~L and ~ of the lead~ng ~nd trall~ng edges 42 and 46 ~orks
well wlth the aforementioned spectrum of included angles ~ of the
shank 28 to yield a tapered shank 28 advantageously orlented
relative to the substrate 24 to provtde high shear and peel
strengths without requiring exeesslve prong materlal
The foregoing measurements are easily made using a Model
100-00 115 goniometer sold by Rame -Hart Inc of Mountain Lakes
New Jersey If more precise measurement is deslred lt wiil be
recognlzed by one skilled in the art that detenminat~on of the
profile vlew origin 36 cuttlng plane 40-40 leading angle ~L
trailing angle ~T base points 50 and 52 75% polnts 44 and 48

WO 94t27461 2 1 6 3 3 3 1 PCT/US94/05115



and the angle ~ of the shank 28 can be advantageously performed by
making a photograph of the prong 22 A model l~00 scanning
electron microscope sold by Amray Inc of New Bedford
Massachusetts has been found to work well for thls purpose If
necessary several photographs may be taken to determine the
~aximum lateral pro~ection 38 ~nd hence either profile view
The shank 28 should longltudinall~ project from the base 26 -
distance sufficient to space the engaging means 30 from the
substrate 24 at an elevation ~h~ch allows the engaging ~eans 30 to
readily tntercept or eng-ge the strands of the rece~ving surface
A relatively longer shank 28 provides the advantage that ~t c~n
penetrate deeper into the receiving surface ~nd thereby allow the
ens~aging means 30 to ~ntercept or engage a greater number of
strands or f~bers Conversely a relatively shorter shank 28
length provides the ~dvantage that a relatively stronger prong 22
results but also provides correspondingly less penetrat~on ~nto
the recelving surface nd may therefore be unsuitable for
receiv~ng surf-ccs such as ~ool or loosely stitched bonded
n~terials which h-ve less densely packed strands or fibers
If a knitted or woven m~terlal recelv~ng surface 1s ut~llzed
a relatively shorter shank 28 having a longitudinal length from
the substrate 2~ to the point or segment of hlghest elevation of
about 0 5 millimeters (0 020 inches) preferably at least about
0 7 ~illimeters (0 028 lnches) ts suitable If a h19h loft
mater1~1 rece1v1ng surface hav1ng a cal~per greater than ~bout 0 9
milli~eters (0 035 inches) 1s utll1zed a rel~tively longer shank
28 havtng greater long~tudinal di~ens1On of at least about 1 2
millimeters (0 047 inches) preferably at least about 2 0
millimeters (0 079 inches) ls more suitable As the shank 28
length increases and shear strength correspondingly diminishes
the density of the prongs 22 of the fastening system 20 may be
increased to compensate for Such loss of shear strength
As described above the longitudinal length of the shank 28
determines the longitudinal spacing of the engaging means 30 from
the substrate 24 The longitudinal spacing is the least
perpendicular distance from the plane of the substrate 24 to the
periphery of the engaging means 30 For an engaging means 30 of

WO 94/27461 2 1 6 3 3 3 1 PCT/US94/05115

l8

constant geometry the longltudtnal spaclng of the engaglng means
from the substrate 2~ becomes greater ~lth lncreaslng
long1tudlnal shank 28 length. A longltudlnal spaclng of at least
about tw ke the stra~d or fiber diameter of the 1ntended recelvlng
surface ~nd preferably about lO t1mes as great as such f1ber or
str~nd dlameter provldes good lntercept10n or engagement and
retent10n of such str~nds or flbers by the engaglng ~eans 30 of
the fasten1ng syste~ 20. ~or the emb3dlment described herein
prong 20 hav1ng a longltud1nal spac1ng of about 0.2 mlll1meters to
about 0.8 mllllmeters (0.008 to 0.03 tnches) works ~ell.
The shape of the cross sectlon of the sh~nk 28 is not
crlt1cal. Thus the shank 28 may be of any cross sectlon deslred
accordi~g to the aforement10ned parameters relating to the cross
sect10n of the base 26. The ~cross section ls the pl~nar area of
any part of the prong 22 taken perpendlcular to the shank 28 or
the engaglng ~eans 30. As noted above the shank 28 1s preferably
tapered to decrease 1n cross sect10n as the d~st~1 end of the
shank 28 and engag1ng means 30 of the prong 22 are longltudinally
and laterally approx1mated. Th1s arrangement provldes
correspond1ng de~re~se 1n the moment of 1nert1a of the shank 28
and engaglng means 30 resultlng 1n a prong 22 of ~ore nearl~
constant stress when separat10n forces are appl1ed to the
fastening s~stem 20 and thereby dimin1shes the quantlty of
superfluous mater1als 1ncorporated 1nto the prons 22.
~ o ~a~ntaln the deslred geometry over a w~de range of prong
22 s1zes a gener~lly unlform rat10 of cross sect10nal areas c~n
be ut111zed to scale the prongs 22. One rat10 whlch generally
controls the overal1 t-per of the prong 22 ls the ratlo of the
are~ of the cross sectlon of the base 26 to the area of the cross
sect10n of the prong 22 at the hlghest elevatlon of the prong 22.
The phrase ~hlghest elevatlon~ refers to the that po1nt or segment
of the shank 28 or the engaging means 30 having the greatest
perpendicular distance from the plane of the substr~te 24.
Typically prongs 22 havlng a base 26 cross sectlonal area to
highest elevation cross sectional area ratio in the range of about
2:l to about 9:1 work well.

WO 94/27461 2 1 6 3 3 3 1 PCT/US94/05115



A generally c1rcular shank 28 whlch tapers from a base 26
dlameter as discussed above ranglng from about 0.~6 oill~æters
to about 1.27 mlllimeters (0.030 to about 0.050 ~nches) to a
hl~hest elevatlon dlameter of about 0.~1 m~lllmeters to about
0.5l m1111meters (0.0l6 to 0.020 lnches) has been found sultable
for the embodiment discussed herein. Speclf~cally a generally
circular shaped cross sectlon of about 0.~6 ml~ eters (0.018
lnches) dlameter at the hlghest elevatlon provldes a cross
sectlonal ~rea t highest elevat~on of bout O.l~ square
mllllmeters (0.0003 square lnches). A gener~lly c1rcular shaped
base 26 cross sectlon of about 1.0 mlllimeters (0.0~0 ~nches)
provldes a base 26 cross sectional area of ~bout 0.81 squ-re
milllmeters (.00l3 square lnches). Thls structure results ln a
ratlo of base 26 cross sectlonal area to hlghest elevat~on cross
sectlonal are~ of about 5:1 whlch ls w~thln the aforementloned
range.
The eng2ging means 30 ~s ~olned to the shank 28 and
preferably ls contlguous wlth the distal end of the shank 28. The
eng-ging means 30 pro~ects radlally away and outwardly from the
per1phery of shank 28 and may further have a vector component
whlch longltud~nally pro~ects l.e. towards or away from the
substrate 24. As used hereln the term -engaglng means~ refers to
an~ protruslon lateral to the perlphery of shank 28 (other than
mlnor asperlties in the per~phery of the shank 28) ~h kh
protrus1On res~sts separatlon or remov~l from ~ recelv1ng surface.
The term perlphery~ oeans the outer surface of the prong 22. The
term ~rad~ally~ means fro- or towards the perpendlcular to the
substrate 2~ whlch perpendtcular passes through the or1gin 36
which 1s generally centered ~lthin the footprint of the base 26.
Partlcularly the lateral protrusion has a vector component
parallel to and faclng towards the plane of the substrate 24. It
is to be recognized that the engaglng means 30 and shank 28 may
have both lateral and longitudinal vector components. It is not
important that a sharply defined terminus of the shank 28 distal
end be apparent or that a demarcation between the shank 28 and
engaging means 30 be discernible at all. It ls only necessary
that a longitudinally orlented face of the shank 28 perlphery be

-

PCT/US94/OS115
W094/27461 21 63331 ~



lnterrupted so that the engaglng ~e-ns 30 h~s ~ face wlth a vector
component parallel to nd facing the plane of the substrate 2~
~ he engaglng means 30 ~a~ have a greater lateral pro~ectton
38 than the shank 28 or vlce-versa as desired As illustrated
in the figures the engaging ~eans 30 is preferably gener~lly
arcuate and may have ~ reentrant curve If the engaglng means 30
has a reentrant curve the engaging ~eans ~0 includes a segment
wh~ch longituttnally ~pprox~ates the substrate 2~ at the base 26
or a locatton laterally spaced fro~ the base 26 thls segoent is
l~terally d{rected towarts the shank 28 although the segment need
not be radially directed tow~rts the orlg1n 36
The engaging means 30 of e~ch prong 22 of the fasten~ng
system 20 may later~lly extend substant~ally ~n the same
direction if a rel-tivel~ unidirectionall~ or~ented peel strength
is deslred or ~ay be rando~ly or~ented to prov~de substanti~lly
~sotropic peel strengths 1n any lateral direction ~he engaging
0eans 30 may be hook-shaped tines ~h~ch pro~ect substant1ally fro~
one slde of the shank 28 definlng a gener~lly convex outllne and
penetrate the opening of the receiv~ng surface to ~ntercept the
str~nds or fibers of the recelv~ng surface at the inner radius of
curvature 5~ of the eng-ging ~eans 30 The interference bet~een
the engaging means 30 and strands or ftbers of the receiving
surface prevents rele-se of the fastening system 20 froa t~e
receiving surface until the peel strenqth or shear strength of the
f-stening syste~ 20 ls exceeded The engaging means 30 should not
radlally pro~ect too far ~n the lateral d~rection other~lse the
engaglng ~eans 30 ma~ not penetrate the open1n~ of the receiving
surface The cross section of the engag~ng ~eans 30 should be
sized to penetrate the openings of the rece1v1ng surface.
The cross sectlonal area and geometry of the engaging ~eans
are not critical so long as the engaging means 30 has
structural integrity which provides suffkient shear and bending
strengths to accommodate the desired peel and shear strengths of a
fastening system 20 having an array of prongs 22 of a given
density For the embodiment described herein a hook-shaped tine
engaging means 30 having a maximum lateral pro~ection 38 from the
center of the base 26 to the remote lateral peripher~ of about

WO 94/~7461 2 1 6 3 3 3 1 PCT/U594/OSIIS



0 79 mill1meters to about 0 90 mlllimeters (0 03 to 0 0~ inches)
is suitable
~ he array of prongs 22 ~ay be of any pattern and density as
deslred to ach1eve the peel and shear strengths requ~red for the
particular appl1cation of the fastening system 20 Gener-lly as
the array dens1ty 1ncreases peel strength and shear strength
proportionately increase 1n a linear fashion The 1ndividu~1
prongs 22 should not be so closely spaced as to ~nterfere with ~nd
prevent the engag1ng means 30 of the ad~acent prongs 22 fro~
~ntercepting strands or f1bers of the rece1v1ng surf~ce If the
prongs 22 are too closely spaced compact1ng or ~att1ng of the
receiving surface strands or fibers may occur occluting the
openings between the strands or fibers Conversely the prongs 22
should not be so distantly spaced s to require an excessive area
of substrate 2~ to prov1de a fastenlng system 20 of adequate shear
and peel strengths
It 1s advant-geous to d1spose the prongs 22 1n rows so that
each prong 22 ls generally equally spaced from the adjacent prong
22 ~he rows are generally or1ented in the ~ach1ne d~rectlon and
cr0ss-mach1ne tirect1On ~ccord1ng to the ~anufactur1ng process
described tnd cla1med below Generally each mach1ne direct1On
tnd cross-machine direction row of prongs 22 shoult be equally
spaced from the adjacent machine direction nd cross-m~ch1ne
direction rows of prongs 22 to provide a generally uniform stress
field throughout the f~sten1ng systee 20 and the rece1vlng surface
wh~en separ-tion forces arc ~ppl1ed to the fasten1ng syste 20 and
the rece1ving surface
As used here1n the tern ~p1tch- refers to the dist~nce
measured e1ther 1n the machlne d1rect1On or cross-nach1ne
direction between the centers of the footpr1nts of the bases 26
of prongs 22 in adjacent rows Typically a fastening system 20
having an array of prongs 22 with a pitch ranging from about 1 02
millimeters to about 5 08 millimeters (0 04 to 0 20 inches) in
both directions is suitable with a pitch of about 2 03
millimeters (0 08 inches) being preferred Adjacent cross-machine
direction rows are preferably offset approximately one-half pitch
in the cross-machine direction to double the distance in the

WO 94/27461 2 1 6 3 3 3 I PCT/US94/05115
.




22

~achine dtrect1On between the ad~acent cross-machlne directlon
rows.
The prongs 22 may be thought of as disposed in a matrix on a
one squ-re centimeter gr1d h-v~ng ~n array of prongs 22 with bout
2 to about 20 ro~s of prongs 22 per centimeter (5 to S0 rows per
inch) in both the machine and cross-mach1ne directions preferably
about 9 rows of prongs 22 per centlmeter (23 rsws per 1nch) in
each direct~on. This grid w~ll result in a fastenlng system 20
having about 4 to about ~00 prongs per square cent~eter (25 to
2500 prongs per square 1nch) of substr-te 24.
The prongs 22 may be made of any then~ally senstt1ve ~ater~l
which ~s stable and shape ret~ining ~hen sol~d but not so brittle
that failure occurs when the fastening system 20 ~s subjected to
separation forces. As used herein ~thenmally sensit~ve~ means a
material which 3radually changes frD~ the solid state to the
liquid state upon the application of heat. Failure 1s considered
to have occurred when the prong 22 has fractured or can no longer
sust~n a reaction in the presence of and when sub~ected to
sepa ntion forces. Preferabl~ the material has an elastic tensile
~odul~s ~easured according to ASTH Standard D-638 of about
2~ 600 000 to ~bout 31 600 000 kilograms per square meter (35 00
to 45 000 pounts per square 1nch).
~ urther the prong 0aterial should h~ve a ~elting polnt low
enough to provide for easy processing and a relatively high
vtscos~ty to proYide a tacky nd tough consistency at temperatures
near the materl~l ~elt~ng po~nt so th~t the shanks 28 may be
stretched ~nd the eng-g~n~ means 30 eas11y formed according to the
method of ~anufacture rec1ted below. It is also important th~t
the prongs 22 be viscoelast1c to allow for more varlatlon in the
parameters affecting prong structure and particularly the
geometry of the engaging means 30. Material having a complex
viscosity ranging from about 20 to about 100 Pascal seconds at the
temperature of application to the substrate 24 is suitable.
The viscosity may be measured with a Rheometrics Model 800
Mechan kal Spectrometer using the dynamic operating mode at a 10
Hertz sampling frequency and 10% material strain. A disk and
plate type geometry ~s preferred particularly with a disk having

WO 94/27461 PCT/US94/05115
~ 21 63331
23

a radius of about 12.5 millimeters and a gap of about l.0
mill1meter between the disk and plate.
The prongs 22 are preferentlally comprised of a thermoplastic
material. The ter~ ~thenmoplast~c~ refers to uncrossltnked
poly~ers of a thermally sensitive ~aterial which flows under the
application of he~t or pressure. Hot ~elt adhesive thermoplastics
are part1cularly well suited to manuf~cture the fastening system
20 of the present 1nvention particularly tn accord~nce ~ith the
process described and claimed belo~. As used hereln the phrase
hot melt adhestve~ refers to thermoplastic compounds nonmally
solid at room temperature whlch become fluld ~t elevated
temperatures and which are ppl~ed in the molten state. Examples
of hot melt adhesives may be found in the ~Handbook Of Adhesives-
Second Ed1tion by Irv~ng Skeist published in 1977 by Van NostrandReinhold Company 135 ~est 50th Street New York New York 10020
wh kh ~s ~ncorporated herein by reference. Polyester and
polyamide hot ~elt adhesives re particularly sultable and
preferred. As used herein the ter~s polyester- nd polyamide-
mean chains having repeat~ng ester and ~ide units respectively.
If a polyester hot ~elt adhesive ~s selected an adhes~ve
halving a complex v1scosity of about 23 ~ 2 Pascal seconds at about
l9~-C has been found to work well. If a polyamlde hot ~elt
adheslve ~s selected an adhesive h-ving a complex v~seosity of
about 90 + lO Pascal seconds at about 20~-C has been found to work
~ell. ~ polyester hot melt adhes1ve ~arketed by the Bostik
Company of M1ddleton Hassachusetts as No. 7199 has been found to
work well. A polyam~de hot ~elt adhes1ve marketed by the Henkel
Company of Kankakee Illlnols under the tradename Macromelt 6300
has been found to work well.
In a second embodiment of the fastening system 20
illustrated by Figure 3 the engaging means 30 may be generally
semispherically (mushroom) shaped. The term semispherical- means
a generally round shape protruding in multiple directions and is
inclusive of hemispheres and spheres but not limited to regular
shapes. This geometry part kularly the generally spherically
shaped engaging means 30 structure provides the advantage that
less disturbance to the strands of the receiving surface typically

WO 94/27461 ~ 1 6 3 3 3 1 PCT/US94/0511

2~

occurs ~hen the engag1ng ~eans 30 ts removed from the receiving
surface. Thls c-uses less vislble damage to the rece1vtng
surface allowing lt to be reused a greater number of times. If
the semispher1cally shaped engaging means 30 is selected the
shank 28 is preferably ~ore nearly orthogonal to the plane of the
substrate 24 to allo~ e~ster penetration ~nto the openings of
the recelv1ng surface and to reduce damage to the recelving
surface as the engaging ~eans 30 is released from the receiv~ng
surface. A shank 28 haYing an angle ~ of about ~0- to about 90-
is su~table.
To provide a prong 22 of the proper proportions and hav~ng a
generally semispher1cal engaging means 30 the engag~ng Deans 30
should radially protrude from the circu~ference of the shank 28
lateral d~stance suff~cient to ~ntercept the strands of the
receiv~ng surface but not protrude so f~r that the ~ass of the
engaging means 30 1s unable to be rigidly supported by the shank
28 or the shank 28 ls otherwise unstable. As the angle ~ of
the shank 28 decreas-s i.e. devlates further froe the
perpendicular the mass of the engaging ~eans 30 relat~ve to the
shank 28 structural integr~ty and cross sectional area becomes
~ore critical.
A tapered shank 28 having the base 26 to highest ekvat~on
cross sectional area and d~ameter ratlos described above and an
angle ~ of the sh~nk 28 of about 80 works ~ell. It is to be
recogni~ed the b1ghest elevat10n ~easurements ~re to be taken fro~
the hlghest elevat~on of the shank 28 nd not frc~ the engaging
~eans 30 .
For an embod~ment as illustrated 1n Flgure 3 which does not
have a smooth transit~on from the shank 28 to the engaging means
and for which the demarcation between the shank 28 and
engaging means 30 is easily determined the imaginary cutting
plane 40 -40 is three-fourths of the perpendicular distance from
the plane of the substrate 24 to the plane tangent to the point
of the engaging means 30 which is longitudinally closest to the
plane of the substrate 24 . The cutting plane 40 -40 is then
used to determine the angle ~ of the shank 28 the leading edge
angle ~L and trailing edge angle ~T as described above.

W O 94/27461 2 1 6 3 3 3 1 PCTrUS94/05115



The engaging means 30' should radially pro~ect in each
lateral direction from the periphery of the distal end 29' of the
shank 28' at least about 25 percent of the diameter of the distal
end 29 of the shank 28, and preferably at least about 38 percent
of such diameter Alternatively statet ~f the diameter of the
distal end 29 of shank 28' iS normalized to l 0 the diameter of
the engag~ng means 30' should be at least 1.5 and preferably at
least 1 75 times the diameter of the distal end 29 of the shank
28'. Furthermore the dia0eter of the b-se 26 should be about
2 0 times the diameter of the distal end 29 of the shank 28 .
The shank 28 height should be about l.5 to about 2 t~es the
diameter of the distal end 29 of the shank 28 to properly
longitudinall~ space the engaging means 30 from the substratc
2~ . The longltudin~l dimension of the engaging means 30 may
range from about 0 5 to ~bout 1 5 times the d~ameter of the distal
end 29 of the shank 28'.
The fastening system 20 of Figure 3 1s made by heatlng the
engaging means 30 and dlstal end of the f~stentng system 20 of
F1gure 2 to at le-st the melt1ng polnt. Th1s is acco~pl1shed by
bring1ng the eng~gtng me~ns 30 ~nd dist~l ents of the prongs 22 to
a heat source long~tudinally directed toward the plane of the
substrate so that the base 26' and the prox~m~l end of the shank
28 are not heated to at le-st the melt~ng point. A su~table
method is to br1ng the highest elevat~on of the prong to withln
about 3 3 mill~meters to about 10.1 m111~eters (0.1 to 0.~
inches) of ~ heat source such s a hot w~re heated to about
~O-C.
The lead1ng edge angle ~L and tra111ng edge angl~ ~T Of the
prong 22 will be s1milar to that of the corresponding hook-shaped
tine style engaging means prong 22 from which the semispherically
shaped engaging means style prong 22 was formed This occurs
~ because the angle ~ of the shank 28 and leading edge and
trailing edge angles ~L and ~T do not substantially change as
the engaging means 30 of tigure 2 is heated and melted to flow
into the engaging means 30 of Figure 3
For the aforementioned Milliken 970026 receiv1ng surface the
engaging means 30 of Figure 3 should preferably have a lateral

WO 94/27461 PCT/US94/05115
21 63331 ~


and longitudinal dimension of about 0 029 millimeters to about
0 032 millimeters ( OOI inches) and be disposed on a shank 28
having ~ base 26 diameter of about 0 30 millimeters to about
0 045 ~illimeters ( 012 to 002 lnches) and a diameter at the
distal end 29 of about 0 016 millimeters to about 0 020
millimeters (0 0006 to 0 0007 ~nches) The distal end 29 of the
shank 28 should be disposed between about 0 ~4 millimeters nd
about 0 50 ~illi~eters ~ 017 ~nches to 020 inches) above the
plane of the substr~te 2~ and the engaging means 30 should have
a l-teral pro~ectton 38 of about 0 56 milli~eters to about 0 70
millimeters (0 022 to 0 028 inches) preferably about 0 6
millimeters (0 025 ~nches)
PROCESS OF MANUFACTURE
~ he fasten~ng system 20 ccording to the present inYention
may be ~anufactured using a ~odified gravure print~ng process
Gravure printing ~s well known ln the art ~5 lllustrated by U S
Patent No ~ 6~3 I30 issued February 17 I988 to Sheath et al
and incorporated hereln by reference to ~llustrate the gener~l
st~te of the art Referring to Figure ~ the substr-te 2~ is
passed through the nip 70 for~ed between t~o rolls a pr1nt roll
72 and a backing roll 74 The rolls 72 and 7~ have substantially
mutually parallel centerlines disposed` generally parallel to the
p7~ne of the substrate 2~ The rolls 72 and 7~ are rotated about
the respective centerl~nes ~nd h-ve generally equal surface
veloc1ties 1n both magnitude ~nd direct~on at the nip po~nt 70
If desired both the print roll 72 and the backing roll 7~ may be
driven by an external motive force (not sh~wn) or one roll driven
by external motive force ~nd the second roll dr~ven by frictlonal
engagement with the first roll An alternating current electric
motor havlng an output of about I 500 watts provides adequate
motive force
The depositing member should be able to accommodate the
temperature of the material of prongs 22 in the liquid st?te
provide substantially uniform pitch between the prongs 22 in both
the machine and cross-machine directions and yield the desired
density of prongs 22 within the array Also the depositing
member should be able to produce prongs havinq various diameters

WO 94/27~61 3 3 3 1 PCT/USg4105115
.



2~

of the base 26 and heights of the shank 23. The phrase
~deposit1ng member~ refers to anythlng which transfers 11quid
prong material from a bulk quant1ty to the substrate 2~ in dosages
corresponding to indiv1dual prongs 22. The term ~deposlt~ ~eans
to transfer prong material from the bulk for~ and dose such
~aterial onto the substrate 2~ ln units corresponding to
lndividual prongs 22.
One suttable depositing member ts a prlnt roll 72 having an
array of one or more cells 76. As used herein the t~r cell-
refers to any cav1ty or other component of the prlnt roll 72
which transfers prong material from ~ source to the substrate 2~
and deposits this material onto the substrate 2~ in discrete
un1ts. This 1s a particularly preferred deposit1ng member.
Another sultable deposit~ng member ~s a print screen (not
shown) havlng apertures or meshes through ~h kh ~olten prong
n~terlal 1s extruded onto the substrate 2~. Th1s 1s
particularly preferred deposlting member if a dense array of
prongs 22 is desired.
The sectional area of the cell 76 taken ~t the surf~ce of
the print roll 72 generally corresponds w1th the shape of the
footprint of the base 26 of the prong 22. ~he sectional area of
thle cell 76 at the surface of the prlnt roll ?2 should be
approximately equal to the desired sh-pe and area of the footprint
of the base 26. The depth of the cell 76 ~n p-rt deten~ines the
long1tudinal length of the prong 22 speclfically the
perpendicular d~st-nce fro~ the base 26 to the polnt or seg~ent of
highest elevat10n. However as the depth of the cell 76 increases
to more than approx1mately 70 percent of the diameter of the cell
76 the longitudlnal dlmens10n of the prong 22 generally remains
constant. This is because not all of the 11quit prong mater~al 1s
pulled out of the cell 76 and deposited on the substrate 2~. Due
to the surface tension and viscosity of the liquid prong material
some of it will remain in the cell 76 and not be transferred to
the substrate 24.
For a prong 22 generally oriented in the machine direction a
blind generally cylindrically shaped cell 76 having a depth
between about 50 and about 70 percent of the diameter is adequate.

WO 94/27461 2 1 6 3 3 3 1 PCTIUS94/05115
.




28

If deslred the cell 76 may be somewhat frustocon k ally tapered ln
shape as shown 1n F1gures l~a nd l4b to accormodate
conventlonal manufacturlng processes such ~s chemlcal etching.
If frustoconlc~lly shaped the tncluded angle of the taper of
the cell 76 should be no oore than about 45- to produce the
preferred taper of the shank 28 and ~ield the base to highest
elevatlon ratios discussed above. If the taper of the cell 76 has
a greater lncluded anqle a prong 22 havlng too ~uch taper ~ay
result. lf the lncluded angle is too small or the cell 76 ~s
cyllndrlcal a sh~nk 28 of generally untform cross sectlon ~ay
result and thereby have areas of hlgher stress. For the
embodi~ent descrlbed hereln a cell 76 havlng an tncluded angle of
about ~5-; a diameter ~t the roll perlphery of about 0.89
mill1Oeters to about l.22 mlllloeters (0.035 to 0.048 inches) and
a depth ranglng from about 0.25 m1111meters to about 0.51
~llli~eters) O.Ol to 0.02 inches produces ~ sultable prong 22.
The prlnt roll 72 and backlng roll 74 should be coopressed
coincldent ~ith the llne connectlng the centerllnes of the rolls
to press the adhesive from the cells 76 1n the pr1nt roll 72 onto
the substrate 2~ and to prov1de suff1c1ent frlctlon~l engage0ent
to drlve the oppos~ng roll lf tt 1s not externally dr1ven. The
backlng roll 7~ should be somewhat softer ind more co~pllant th~n
the prlnt roll 72 to provtde cushlonlng of the prong oaterlal ~s
it is deposlted on the substrate 24 from the prlnt roll 72. A
backlng roll 74 hav1ng ~ rubber coat~ng ~lth a Shore A duroneter
hardness of about 40 to bout 60 ts su1table. The rolls 72 and 7~
oay be pressed together w~th such a force that an l~presslon 1n
the mach~ne dlrectton of about 6.4 mllllmeters to about l2.7
mllllmeters (0.25 to 0.50 1nches) ts obtalned. As used hereln the
term ~lmpression~ refers to the contact area of the softer roll on
the substrate 24 as it passes through the nip 70.
The prlnt roll 72 is preferably heated to prevent
solidificatlon of the prongs 22 during transfer from the source
through the deposltion on the substrate 24. Generally a print
roll 72 surface temperature near the source materlal temperature
is desired. A print roll 72 temperature of about 197-C has been

WO 94127461 PCTIUS94/05115
~ 2 1 6333 1
29

found to work ~ell with the polyester hot melt adhesive marketed
by the Bostik Company of ~iddleton Massachusetts as No ~l99
It is to be recogn ked that a ch111 roll may be necessary if
the substrate 2~ is adversely affected by the heat tr~nsferred
from the prong materi~l If a chill roll is desiret it may be
lncorporated into the backing roll 7~ using means well known to
one sk~lled ~n the art This arrangement 1s of~en necessary lf a
polypropylene polyethylene or other polyolefin~c substrate 2~ is
used
The material used to fonn the indlvidual prongs 22 must be
kept in a source which provldes for the proper temperature to
apply the prongs 22 to the substr-te 2~ Typ~c~lly a temperature
slightly above the melting polnt of the ~aterial is desired The
material is considered to be at or above the ~melting polnt~ 1f
the material is partially or ~holly in the liqu~d state If the
source of the prong materi~l 1s kept at too high temperature
the prong material may not be viscous enough and may produce
engaging me~ns 30 whteh laterall~ connect to the prongs 22
adjacent 1n the machine direct~on If the material tenperature 1s
very hot the prong 22 ~ill n ow lnto a small somewhat
semispherically shaped puddle and an engaging means 30 will not be
formed Conversely if the source temperature ~s too lo~ the
prong materlal ~ay not transfer from the source to the deposlting
member or subsequently ~ay not properl~ transfer fro~ the
deposit~ng ~ember to the substrate 2~ ~n the des1red array or
pattern The source of the ~ater1al should also ~mpart
g~nerally un1fore cross-~ach1ne direction temperature profile to
the mater1al be in communlc~tion with the means for depos~ting
the adhesive material onto the substrate 2~ and eas11y be
replenished or restocked as the prong material becomes depleted
A suitable source is a trough 80 substantially coextensive
of that portion of the cross-machine dimension of the print roll
72 which has cells 76 and adjacent thereto The trough 80 has a
closed end bottom an outboard side and ends The top may be open
or closed as desired The inboard side of the trough 80 is open
allowing the liquid material therein to freely contact and
communicate with the circumference of the print roll 72

WO 94/27461 2 1 6 3 3 3 1 PCTJLJS94/05115



The source is externally heated by known means (not shown) to
maintain the prong material in a liquid state and at the proper
temperature. The pre~erred temperature is above the melting po1nt
but belo~ that ~t which a significant loss of viscoelasticity
oçcurs. If desired the llqu1d mater~al inside the trough 80 ma~
be mixed or recirculated to promote homogeneity and an even
temperature distribution.
Juxtaposed ~lth the bottom of the trough 80 ~s a doctor blade
82 which controls the amount of prong mater1al appl1ed to the
print roll 72. The doctor blade 82 and trough 80 ~re held
stat~on~ry as the print roll 72 1s rotated allo~ing the doctor
blade 82 to wlpe the circumference of the roll ~2 and scrape an~
prong material ~hich is not disposed with1n the indiY~dual cells
76 from the roll 72 and allows such material to be recycled. Th1s
~rrangement ~llows prong nater1al to be depos1ted from the cells
76 to the substr~te 2~ in the desired ~rra~ ~ccord~ng to the
geometry of the cells 76 on the clrcumference of the pr~nt roll
72. As seen ~n Figure ~ the doctor blade 82 is preferent~ally
d1sposed 1n the hori~ontal plane part k ul~rly the hor k ontal apex
of the pr~nt roll t2 wh~ch ~pex 1s upstrea~ of the n~p point 70.
After being deposited onto the substrate 2~ the prongs 22
are severed from the print roll 72 and the cells 76 by a sever~ng
means for severing 78 the prongs 22 1nto the engaging ~eans 30 of
the fastening s~stem 20 ~nd a moll. As used here~n the ten
~411- refers to ~n~ mater~al severed fro~ the prong 22 ~nd wh kh
does not fora part of the fastening system 20.
The severing means 78 should be ad~ustable to accommodate
various stzes of prongs 22 ~nd l~teral pro~ect~ons 38 of engaging
means 30 ~nd also provide uniformity throughout the cross-machtne
direction of the array. The term ~severing means- refers to
anything which longitudinally separates the moil from the
fastening system 20. The term ~sever~ refers to the act of
dividing the moil from the fastening system 20 as described above.
The sever~ng means 78 should also be clean and should not rust
oxidize or impart corrodents and contaminates (such as moil
materlal) to the prongs 22. A suitable severing means is a wire
78 disposed generally parallel to the axis of the rolls 72 and 7

WO 94/27461 PCT/US94/05115
~ 2 1 6333 1
31

and spaced fro~ the substrate 24 a distance which 1s somewhat
greater than the perpendicular distance from the highest elev~tion
of the sol1d1f1ed prong 22 to the substrate 2~.
Preferably the wire 78 is electr1call~ heated to prevent
build-up of the molten pron~ materlal on the severing means 78
accommodate any cool1ng of the prongs 22 which occurs between the
ttme the prong materia? leaves the héated source and severing
oc:curs ~nd to promote lateral stretching of the engaging means 30.
The heating of the sever~ng means 78 should also prov~de for
un1form temper-ture distribution in the cross-mach~ne d~rect1On
so that an array of prongs 22 having substantiatly ~nifon~
geometry is produced.
Generally as the prong material temperature ~ncreases
relatlvel~ cooler hot ~ire 78 temperature sever1ng means can be
accommotatet. Also as the speed of the substrate 24 is
decreased less frequent cooling of the hot w1re 78 occurs as each
prong 22 and noi1 are severed making a relatively lower wattage
hot wire 78 more feasible at the same temperatures. It should be
recogntzed that as the temper~ture of the bot w1re 78 ls 1ncre~sed
~I pr~ng 22 havlng a generally shorter shank 28 length will result.
Conversely the shank 28 length and l~teral length of the engaging
means 30 will be incre-set in inverse proportion as the
temperature of the hot wire 78 is decreased. It is not necessary
1;hat the sever~ng means 78 actually contact the prong 22 for
xevering to occur. The prong 22 may be severed by the radiant
heat emitted fro~ the severlng means 78.
For the embodiment described here~n a round cross section
nickel-chromium wire ~8 having a diameter of about 0.51
millimeters (0.02 inches) heated to a temperature of about 3U -C
to about 416-C has been found suitable. It will be apparent that
a knife laser cutting or other severing means 78 may be
substituted for the hot wire 78 described above.
It is important that the severing means 78 be disposed at a
position which allows stretching of the prong material to occur
prior to the prong 22 being severed from the moil. If the
severing means 78 is dlsposed too far from the plane of the
substrate 24 the prong material will pass underneath the severing

WO 94/27461 PCT/US94/05115
2 1 6333 1 ~



means ~8 ~nd not be intercepted by it forming a ver~ long
engaging means 30 which will not be properly spaced fro~ the
substrate 2~ or ad~acent prongs 22. Conversel~ if the severing
means 78 is disposed too close to the plane of the substrate 2~
the sever1ng means 78 will truncate the shank 28 and an eng~glng
me~ns 30 ma~ not be for~ed.
A hot wire sever1ng means 78 tisposeJ approxim~tel~ l4
mill~meters to 22 milli~eters (0.56 to 0.88 lnches) preferably
about l8 0illl~eters (0.72 inches) ~n the machine direct~on fro~
the nip po~nt 70 appro%imatel~ 4.8 mlll~eters to ?.9 m~llimeters
(O.l9 to 0.3l ~nches) preferably about 6.4 milli~eters (0.25
inches) radially outward from the backing roll 74 and
approximately l.5 ~lllimeters to approxi~ately 4.8 ~ill1meters
(0.06 to O.l9 ~nches) prefer~bly about 3.3 milltmeters (0.13
inches) radially outwardly from the pr~nt roll 72 1s adequately
positioned for the process of ~anufacture disclosed here~n.
In operatlon the substrate 24 ~s transported 1n a f1rst
direction relattve to the depos1t1ng member. ~ore p~rticularl~
the substrate 24 1s transported through the nip 70 preferentially
drawn by a take-up roll (not shown). Thls provldes clcan area
of substrate 24 ~or cont~nuous depos~t~on of pronqs 22 and re00ves
the portions of the substrate 24 h~ving prongs 22 deposited
thereon. The d~rection generally parallel to the pr~ncipal
direction of transport of the substrate 24 as it passes through
the n1p 70 1s referred to as the ~achine direct~on.- The ~ch~ne
t1rect10n as 1ndicated by the arrow 75 of Figure ~ is gener~
orthogonal the centerl~ne of the print roll 72 and backing roll
7~. ~he direction gener~ orthogonal to the mach1ne direction
and parallel to the plane of the substrate 2~ is referred to as
the ~cross-machine direction.~
The substrate 24 may be drawn through the nip 70 at a speed
approximately 0% to approximately lC% greater than the surface
speed of the rolls 72 and 74. This is done to minimize bunching
or puckering of the substrate 24 near the means for severing 78
the prongs 22 from depositing member. The substrate 2~ is
transported through the nip 70 in the first direction at about 3
to about 31 meters per minute (10 to lO0 feet per minute).

WO 94/27461 PCT/US94/05115
21 63331
33

~ he angle of the shank 28 can be 1nfluenced by the rate of
transport of the substr-te 2~ past the nip 70 If prongs 22
having a shank angle ~ more nearly perpendicular to the substrate
2~1 ls desired a slower rate of transport of the substrate 2~ in
the f1rst direction is selected Conversely lf the rate of
transport 1s increased the angle ~ of the shank 28 decreases and
al~ engag1ng means 30 have a greater lateral pro~ect10n 38 w111
result
If des1red the substrate 24 may be lncl1ned t an angle t.
approximately 35 to approx1mately 55 , preferably ~bout ~5 fro~
tl~e plane of the n1p 70 towards the back1ng roll 7~ to ut111ze the
v~scoelastic nature of the prong mater1al and properly orient the
engaging means 30 in the lateral d1rect10n as well as
long1tud1nal direct10n ~his arrangement also provides a greater
force to extract the prong mater1al from the cell 76 and to pull
the prong 22 way fro~ the pr1nt roll 72 The angle 7 from the
plane of the n1p 70 should be 1ncreased ~s a lesser angle ~ of the
shank 28 1s des1red Also increasing the angle ~ of dev1at10n
from the plane of the nip 70 has a weak but positive effect to
produce engaging means 30 hav1ng a greater lateral pro~ection 38
After depos1ting prong mater1al fro~ the cell 76 onto the
slbstrate 2~ the rolls 72 and 74 continue rotation in the
direct10ns 1ndicated by the arrows 75 of Figure ~ This results
in a period of rel-tive displ-cement between the transported
substrate 2~ ~nd the cells 76 dur1ng which per10d (pr10r to
sever1ng) the prong mater1al br1dges the substrate 2~ and print
roll 72 As rel~t1ve d1splacement 1ncreases the prong mater1~1
i~ stretched unt11 severing occurs and the prong 22 separated from
the cell 76 of the print roll 72 As used here1n the term
~stretch~ means to increase in linear dimens~on at least
portion of which increase becomes substantially permanent for the
life of the fastenlng system 20
As discussed above it is also necessary to sever the
individual prongs 22 from the print roll 72 as part of the process
which forms the engaging means 30 When severed a prong 22 is
longitudinally divided into two parts a distal end and engaging
means 30 which remain with the fastening system 20 and a moil (not

WO 94/27461 PCT/US94/05115
2 1 6333 1 ~



shown) ~h1ch remains with the pr~nt roll 72 and may be recycled
as desired. After the prongs 22 are severed from the moil the
fastening system 20 is allowed to free~e prlor to contact of the
prongs 22 with other ob~ects. After sol1difkatlon of the prongs
22 the substrate 2~ ~ay be ~ound ~nto a roll for storage as
desired.
A nonlimit~ng illustration of the process shows the prong
material to be disposed ~n the trough 80 and heated by means
commonly known to one sktlled 1n the art to a te~perature
somewhat above the melting polnt. If a polyester resin hot melt
adhesive is selected a materlal temperature of approximately
177-193-C preferably about 186-C has been found suitable. If a
polyamlde resin is selected a material temperature of
approximately 193-213-C preferably about 200-C has been found
sultable. A one side bleached kraft paper substr-te 24 about
0.008 to about 0.15 millimeters (0.003 to 0.006 inches) ~n
thickness works well with hot melt adheslve prongs 22. ~he prongs
22 are ~oined to the bleached slde of the kraft paper substrate
2~.
For the tllustr-ted operation described herein print roll 72
having an array of about 5 cells 76 per centimeter tl3 cells 76
per 1nch) ln both the mach~ne direction and cross-Dach~ne
direct~ons ~elding gr~d of about 26 cells 76 per square
centimeter (169 cells 76 per square inch) ~s sultable. This grid
tens~t~ may be adv~ntageousl~ used w~th ~ prlnt roll 72 h~v~ng a
diameter of about 16 centimeters 16.3 inches) ~lth cells 76 about
1 m~ll1meter (0.045 ~nches) in diameter and about 0.8 ~1111meters
(0.030 inches) deep. A backing roll 74 hav~ng a diameter of about
I5.2 centimeters (6.0 inches) and ~ertically registered has been
found to work well with the aforementioned print roll ~2. The
rate of transport of the substrate 24 ~s about 3.0 meters per
minute (10 feet per minute).
A nickel-chromium hot wire 78 having a diameter of about 0.5
millimeters (0.02 inches) disposed approximately 18 millimeters
(0.72 inches) from the nip point 70 in the machine direction
approximately 0.3 millimeters (0.13 inches) radially outwardly
from the print roll 72 and approximately 6.~ millimeters (0.25

WO 94/27461 PCT/US94/05115
~ 21 63331



inchesJ radially outwardly from the backing roll 7~ ts heated to a
temper-ture of about 382 C The fastening system 20 produced by
this operation is substantially similar to that illustrated by
Fl~ure 1 whlch fastening system 20 may be dvantageously
incorporated ~nto the illustrative artkle of use discussed below
~ ithout being bound by any p~rticular theory lt is bel~eved
th~t the geometry of the engaqing means 30 1s governed by the
ellstic properties of the hot melt adhesive used to ~ke the prong
22 and the difference 1n the temperature between the tr~11ing edge
~6 and the leading edge ~2 of the prong 22 ~h~ trall1ng edge ~6
of the prong 22 is shielded and insulated frDe the heat
originating from the severing ~eans 78 Conversely the leading
edge ~2 is directly exposed to the heat of the severing means 78
wh~ch causes the le-ding edge ~2 to sol~dify or freeze after the
tra~ling edge ~6 Thls causes elongatlon of the leading edge ~2
and contractlon of the trailing edge ~6 relative to each other
As this temperature difference 1s increased a relatively longer
engaging me~ns 30 ls formet.
If destred a fastening system 20 hav~ng relatively very
small prongs 22 (not shown) ay be ~ade by forming a natural
pattern from the prlnt roll 72 As used herein the term ~natural
pattern~ refers to array of prongs 22 resulting from a pr~nt roll
72 which does not have cells 76 disposed thereon but ~nstead
which utilizes the surface of the roll 72 to deposit the molten
prong mater1~1 rather than the cells 76. Thus the pattern of
prongs 22 is fonDed by the clearance between the doctor blade 82
and the print roll 72 nd to a lesser extent by the surface
finish of the print roll ~2.
The doctor blade 82 should be adjusted to provide about a gap
of about 0.03 millimeters to about 0 08 millimeters (0 001 to
0 003 inches) in radial clearance from the print roll 72 To form
a natural pattern the very small sized prongs 22 resulting from
such a print roll 72 are advantageously utilized with a
reticulated foam receiving surface that does not have strands and
openings therebetween but rather incurs localized elastic
deformations which resist separation of the fastening system 20

WO 94/27461 PCT/US94/05115
2 1 6333 1 ~



Referrlng to ~gure 5 if a fastening system 20 of more
nearly 1sotropic peel strength 1s desired such a fasten1ng system
may be formed by modify1ng the f-stening system 20 of Figure
l through a second stage dlfferenti-l temperature process As
illustrated in Figure S the f-stening system 20 of F1gure 1 is
further processed to provide shanks 28 with engaging means 30
which radially extend from the shanks 28 in var10us lateral
direct10ns of a generall~ r~ndo- orientation ~he phrase random
orientation~ ~eans having lateral pro~ect~ons 38 ~nd profil~
views ~hich sign~ficantly deviate 1n d~rect~on from those of the
nearby prongs 22 .
Without belng bound by any particular theory it is believed
that this structure ~s ccomplished b~ establ~shing ~ temperature
differential between the profile surfaces or lead~ng surfaces ~2
and the trall~ng surfaces ~6 of the prongs 22 of the fastening
system 20 of Flgure I and that such temperature d~fferent~al m~y
be enha~ced by radi-tlon or preferably convection.
It ~s also believed that as a result of attain~ng
temperature d1fferent~al of the leading surface ~2 or the
proflle surfaces relattve to the trailing surface ~6 the
engaging means 30 w111 substantially change or even reverse the
orient~tion of lateral projection 38 providing a prong 22
which ls oriented in a direction other than that wh~ch occurred
when initlall~ cooled or frozen ~he t~fferential temperature ~ay
be establlshed by ~ny source kno~n to one sk~lled ~n the ~rt such
as ~ he-ted wire or metal element nd preferably an air gun 84
disposed above the prongs 22 and capable of pro~ldlng a directed
temperature differential to the fastening system 20
It is desired that the directed temperature d~fferential
source direct an air current towards the fastening system 20
within about + 90 of the first direction of substrate 24
travel which is the machine direction As used herein~ the
phrase ~+ 90 of the first direction~ means a d1rection having a
vector component generally perpendicular to or generally counter
to the first direction of travel of the substrate 24 and is

WO 94/27461 PCTIUS94/05115
~ 2 1 63331


lnclus1ve of the directlon generally opposlte the first direction
of travel
If the directed temperature differential source 8~ ls
dlsposed at an angle of about l80 relatlve to the first direction
of travel of the substrate 2~ the source 8~ 1s directed towards
the leadlng surfaces ~2 of the prongs 22 of the fastening
system 20 and generally opposite the machlne directlon of the
process descrlbed ~nd clalmed herein Dlrectlng the temperature
differentlal of source 8~ dlrectly towards the leadlng surface
~2 of ~ prong 22 w~ll result in the lateral pro~ectlon 38 of
the engaglng means 30 rotatlng to change the orient~tlon of the
lateral pro~ection about l80 Prongs 22 disposed somewhat to
the slde l e in the cross-machine direction of the directed
temperature dlfferentt~l source 8~ wlll not h~ve the engaglng
means 30 rotated about 180 but lnstead en~aglng means 30
~ore nearly rotated about 90- ~hus it ls apparent that a
d~rected temper~ture dlfferentl~l source 8~ oriented ln the
cross-~achlne direct10n wlll provlde a fastenlng syste~ 20
havlng prongs 22 wlth vartous lateral orlentatlons ln the
cross-mach~ne d1rect10n according to the prong 22 posltion
relattve to the temper~ture differential source 84
An air gun 8~ discharging air at a temper-ture of about 88 C
at a distance of about ~6 centimeters (18 1nches) from the
substrate 2~ 1s a sultable dlfferentlal temperature source A
133-3~8 serles he-t gun sold by the Dayton Electrlc ~anufactur~ng
Ccmpany of Chlcago Illlnols oriented at about ~5- relatlve to the
plane of the substrate 2~ and t1sposed about ~6 centimeters (l8
inches) from the prongs produces a fastenlng syste~ 20 pattern
substantlally slmll~r to that shown ln Flgure 5 It wlll be
apparent to one skllled in the art that a one or more hot wires
disposed above the prongs 22 and oriented in the machine
d~rection will produce a fastening system 20 having cross
machine directionally oriented engaging means 30 in a regular
somewhat strlped pattern
Without being bound by any theory it is believed that the
change in orientation of the engaging means 30 occurs due to the
cooling of the profile surfaces or the leading surface ~2 of the

WO 94/27461 PCT/US94/0511~
2 1 6333 1 ~

38

prong 22 relative to the traiting surface ~6 whlch may occur
if the temperature of the discharged a1r from the directed
temper~ture source differential source 8~ is less than the
temper~ture of the periphery of such profile surfaces or leading
surface 42 . The temperature differential resulting from the
cooling causes contract~on of the portion of the prong 22
towards which the temperature differential sourGe 8~ is directed.
This contraction ~ay result in a change in the orientation of the
engaging ~eans 30 and lateral projection 38 , due to the
differential cooling of the leading surface ~2 relattve to the
trailing surface 46 . ~ithout being bound by further theory it
is believed that relief of residual stresses which occur during
cooling may influence the change in orientat10n of the lateral
project~on 38
It ~ill be further ~pparent to one skilled tn the art that
other var~at10ns are fe-sible. For example a prong 22 having an
engaging means 30 protruding ln more than one direction may be
formed or free formed prongs 22 may be produced b~ commonly kno~n
methods other than gravure printlng. If desired only one roll
m~y be ut11ized ~n the manufacturing process prov~ding the
substrate 24 contacts at least about l80- of the periphery of such
roll.
It is frequently desirable to have a fastening system 20 of
the present ~nvention with the maximum lateral projection 38 of
the prongs 22 oriented in a direction other than the ~achine
d~rect10n. For example when using the present 1nvention ~s the
fastening means of a disposable diaper it ls desirable that the
maximum lateral projection 38 of the prongs 22 be or~ented ln a
direction substantially perpendicular to the direct~on of travel
of the disposable diaper on the manufacturing line. A diaper
manufacturing line requires complex and expensive machinery to
cut reorient and apply the fastening system 20 if the maximum
lateral projection 38 of the prongs 22 are oriented in the machine
direction. A fastening system 20 of the present invention
produced with the maximum lateral projection 38 of the prongs 22
oriented in the cross-machine direction however would not
require re-orientation before being applied to a disposable

WO 94/27461 PCT/US94/05115
~ 2 1 6333 1


d~aper It is therefore very advantageous to be able to
manufacture the fastening system 20 of the present invention with
the maximum l~teral pro~ection 38 of the prongs 22 oriented 1n
direction other than the m~chine direction
There are two angles wh1ch re made by the shank 28 of prongs
22 produced by this process The shank 28 makes an angle ~ w~th
the plane of the substrate 2~ as discussed hereinbefore and the
shank 28 lso ~akes n az1muthal angle (indicated by a letter A
F~g 7) relative to the mach1ne direct10n of the substrate 24 As
used here~n the tera ~az~muthal angle~ refers to the angle the
maximum later~l pro~ection 38 makes rel-t~ve to the ~achine
d~rection of the substrate when viewed from above As used herein
~viewed from above~ refers to viewing the prongs 22 from a
direction which is perpendicular to the pl-ne of the substrate 24
The ter~ ~machine dlrection~ refers to the direct~on generally
parallel to the pr~nciple direction of transport of the substr~te
2~ as it passes through the nip 70 and is indicated by an arrow
in F~gure 7 The azlmuthal angle 1s ~easured by first
determining the maxi~u~ lateral pro~ect10n 3a of the prong 22 as
disclosed herelnbefore As shown in Figure ~ the az1~uthal angle
1ndicted by the letter A ls the angle rel-t~ve to the machlne
direction which ts ~ade by 11ne 60 drawn parallel to the maximum
lateral projection 38 when viewed from above The ~zimuthal angle
A c~n be ~e~sured relat1ve to the machine d~rect10n ~n elther the
clockwisc or counter-clockw1se d1rection but the az1muthal anglc
will not be greater than I80 . ~ fasten1ng syste~ 20 sultable for
use on a t~sposable d1-per w111 preferably have prongs 22 with an
azimuthal angle such that the max~mum lateral pro~ect10n 38 w~ll
be oriented in a t1rection hav1ng a vector component perpendicular
to the machine direct~on of the substrate 24 Thus the prongs 22
may have an azimuthal angle greater than 0 degrees between about
I degrees and about 180 degrees generally the azimuthal angle
will be greater than about 20 degrees (20 - I80 ) greater than
about 45 degrees (45 - 180 ) or greater than 60 degrees (60
I80 ) The azimuthal angle of the prongs 22 made using the
process described herein will preferably be from about 20 degrees
to about 160 degrees more preferably from about 45 degrees to

WO 94/27461 PCTlUS94/05115
21 63331 ~
~o

about 135 degrees and ~ost preferably from about 60 degrees to
about 120 degrees. In a preferred embodiment shown ~n Figure 7
the azimuthal angle of the prongs 22 wlll be about 90 degrecs.
A ~ethod for impart~ng an azimuthal ~ngle to the fastening
system 20 ls to bias the prongs 22 of the fastening system 20
whtle the prongs 22 are partlall~ or wholl~ ~n a liquid state. As
used herein the term ~blas- refers to providing a force or
1nfluencing means ln a directlon hav1ng a vector co~ponent
perpendicular to the machine direction of the substrate 24. The
prongs 22 ~ay be biased when they are ne~ly fonaed and h~ve not
yet cooled and solidified and are still malle~ble or the prongs
22 may be biased after they have cooled nd solidified by
reheating the prongs 22 so that they are ~alleable and ~ill turn
when biased. There are a number of methods ava~lable to bias the
prongs 22 so as to 1mpart an azlmuthal angle.
A suitable ~ethod for impart1ng an azi~uthal angle ~s to
bias the prongs 22 by causing gravitational forces to act upon the
prongs 22 wh~le the prongs 22 are partially or wholl~ in a l~qu~d
state such that the gravitational forces will pull the prongs 22
to the desireJ az~uthal angle. This can be accomplished by
tilting the substrate 24 so that the plane of the substrate 24
when viewed ~n the 0achine directlon would not cut
perpendicularl~ through a plum line but rather would form an
angle other than 90 degrees with a plum l~ne. As the prongs 22
are printed and severed the angle 1nd~cated by the letter H 1n
F~gurc 8 of the substrate 24 rel~tive to the horizontal allo~s
gravitat~onal forces to act upon the dist~l ends of the shanks 28
and engag~ng ~eans 30 nd pull the prongs 22 to~ard the
longltudinal s1de of the substrate 24 having the lower altitude.
Preferably the print roll 72 and the backing roll 7~ together ~re
tilted or raised on one end from the horizontal as shown in
Figure 8 so that as the substrate 24 passes through the nip 70 of
the rolls the longitudinal edges of the substrate 24 will be at
nonequal altitudes and the gravitational forces indicated by the
letter G in Figure 8 will act upon the prongs 22 to give the
shank 28 an angle ~ with the substrate 24 and an azimuthal angle A
(neither angle ~ or angle A are shown in Figure 8). The substrate

WO 94127461 2 1 6 3 3 3 1 PCT/US94/05115

~1

24 should be tilted so that the plane o- the substrate 24 fonns an
angle relative to the hor kontal of at least about lS degrees
Preferably the plane of the substrate 24 will be at an angle of at
le~st 30 degrees
Another su1table method for i~parting ~n azimuthal angle ls
to bias the prongs 22 by pplylng a pressure differentlal across
the plane of the substrate 2~ whtle the prongs 22 ~re partlally or
wholly in a llqu1d state such that the prongs are forced or drawn
to the deslred azimuthal angle ~his Ry be acco~pl1shed by
flowlng a llquld or gas cross the plane of the substrate 2~ ln ~
direction havlng vector component perpendlcular to the ~Rchlnc
directlon The pressure d1fferentlal wlll c~use the prongs 22 to
turn or reorient~toward the slde of the substrate having the lower
pressure Preferably the pressure dlfferentlal across thc
substr-te 2~ ls ach1eved by creatlng ~ hlgh pressure from one slde
of the substrate 24 uslng ~ir ~ets ~lr needles or other me~ns
well known 1n the art However the pressure differentlal across
the substrate 2~ may lso be achleved b~ produclng a low pressure
(i e v~cuu~ or part1-1 v~cuum) fro~ one slde of the substrate
2~ or by cre-tlng ~ hlgh pressure fro~ one s~de of the substrate
2~ and at the same t~me ereating a low pressure from the other
s1de of the substr-te 24 The slde of the substrate 24 which
represents the h1gh pressure or low pressure side and the angle
relatlve to the ~ach~ne d1rectlon at ~hlch the fluld flo~s ~s
de end~rt upon the ~zl~uth~l ~ngle deslred ~he fluid ~ed1um usd
will preferably be lr though other g-ses and liqulds ~ay also be
used As used herein the term hlgh pressure~ refers to ~
pressure greater than the amblent pressure of the air or other
fluid whlch sur~ou~ds the prongs 22 as they are being azlmuthally
angled As used herein the term ~lo~ pressure~ refers to a
pressure less than the ambient pressure of the air or other fluid
wh k h surrounds the prongs 22 as they are be~ng azimuthally
angled
It should be understood that it would also be suitable to
have the hlgh pressure and/or low pressure originating from other
tllan the sldes of the substrate 24 That ls the high pressure
source and/or low pressure source may be positioned such th~t the

WO 94/27461 PCT/US94/05115
21 63331 ~


prongs 22 are forced and/or drawn in ~ore than one dlrect10n
giving the fastening system 20 a more isotrop k pee1 strength. As
a nonlimiting example a vacuum source may be tisposed near the
sides of the substrate 2~ and a pressure source disposed near the
middle of the substrate 2~ such that the ~aximum lateral
pro~ection 38 of the prongs 22 will be lnfluenced substantially
away fro~ the middle of the substrate 24 and toward the sides of
the substrate 2~.
~ hen ~ pressure differential 1s used to ~part an azi0uthal
angle to the prongs 22 frequently turbulence ~n the chosen flu~d
mediu~ ~ill cause some of the prongs 22 to scatter or acquire ~n
undesired azimuthal angle. To minim ke the incidence of prongs 22
scattering it is desirable to minimize the turbulent flow of the
flu1d ~edium and malnta~n a more strea~l1ne or l~m~nar flo~.
There are a number of ~ethods avail~ble to produce substant1ally
lamin~r flow.
One ~ethod of produc1ng a substantially laminar ~o~ 1s
through the use of one or more no~zles or flow ampl1fiers to
i0part controlled d1rect10n to a flow. As a non-11mitlng example
two commercial air flow ampllfiers 902 ~ll be used ~n tandem.
The f1rst alr flow ~mplif1er 902 (indicated by the letter P ln
F~g. 9) has the disch-rge flow of its outlet directed across the
substrate 2~. The second air flow amplifier 902 (indicated by the
letter V 1n F1g. 9) has the suction of ~ts ~nlet drawing fro~
across the su~strate 2~. The discharge flow of the first a1r flow
~pl~f~er P is drawn lnto the 1nlet of the second a1r flo~
~mpl1fier V creating a substant~ally ltnear air draft. Ihe a1r
flow amplifiers 902 are oriented relat1ve to the substr~te 2~ to
produce a low veloc~ty 11near a1r draft ln a cross-rachine
direction. The preferred location of the linear air draft is
immediately down stream of the cutting hot wire ~8 (not shown in
Figure 9). Extraneous air current may be eliminated by the use of
an enclosure (not shown) to surround the area where the linear air
draft is applied. Suitable air flow amplifiers are commercially
available from Vortec Corporation of Cincinnati Ohio and marketed
as Transvector Model 912/952 having a 25-lOO SCFM rating. The

WO 94/27461 PCT/US94/05115
~ 21 63331


required a1r pressure may vary but about l pound per square 1nch
to about lO pounds per square 1nch of ir pressure ~orks well
Another su1table method for impart1ng an azi~uthal angle to
the prongs 22 is to blas the prongs 22 by mechanically turn1ng or
physlcally dragg1ng the prongs 22 wh11e they ~re part1ally or
~holl~ tn a liquid state A non-lim~t1ng exumple of thts is the
use of an osc111at1ng or rotat1ng severing me~ns e g hot w1re
(not shown) to force or drag the prongs 22 to the des1red
azimuthal angte as the prongs 22 are cut There ~111 be many
other methods of accompl1sh1ng th1s ~h1ch w~ll be apparent to one
sk111ed 1n the art
A prong 22 having an az1muthal angle can be p~oductd us1ng a
cell 76 having a ma~or axis and m1nor axis w1th the ~inor axis of
the cell 76 or1ented 1n a d1rect10n other than the mach1ne
direct10n of the prlnt roll 72 ~1thout beinq bound by any
p~rt1cular theory 1t 1s bel1eved that a cell 76 hav1ng a ma~or
axls and a m1nor ax1s wlll produce ~ prong 22 havlng a bend~ng
ax1s and weak ax1s and that the forces of graY1ty w111 act upon
the prong 22 to pull the d1stal end 29 and engaglng ~e~ns 30 of
the prong 22 generally ln the d1rectlon of the weak x1s
Although a prong 22 produced uslng a cell 76 of this type does not
need to be biased to azi0uthally angle and will orient generally
1~ the d1rect10n of the weak ax1s without b1as1ng a cell 76 of
th1s type does p~oduce prongs 22 wh1ch re more easlly affected by
b1aslng s descrlbed here~nabove
~ hen the aspect ratlo of the sect10nal area of a cell 76
t~ken at the surface of the pr1nt roll 72 1s greater than 1:1, the
sectlonal area of the cell 76 at the surface of the prlnt roll 72
wlll have a longer d1mens10n and a shorter d1menslon generally
perpend1cular to the longer d1mens10n As used here1n the term
~ma~or ax1s~ w111 refer to the longer dimens10n of the sectional
area of the cell 76 at the surface of the pr1nt roll 72 and as
used herein the term ~minor axis~ will refer to the shorter
d1mension of the sectional area of the cell 76 at the surface of
the print roll 72
Because the sectional area of the cell 76 at the surface of
the pr~nt roll 72 generally corresponds to the footpr1nt of the

PCTIUS94/05115
WO 94/27461
2~ 63331 ~


prong 22 a cell 76 havlng a ma~or ax1s and m~nor axis wtll
produce a prong 22 havtng a footprtnt wtth a ~a~or axts ~nd ~lnor
axis wh1ch generally correspond w1th the m~or axls and minor axts
of the cell 76. The ~eak ~xls of the prong 22 ~tll generally
correspond ~lth the ainor ~x1s of the footprtnt ~nd the bendtng
axis of the prong 22 ~tll generally correspond w~th th~ ~ajor axls
of the footprtnt.
As a nonltmtting exarple of a cell 76 whtch ~tll produce a
prong ~aving a weak axls ~tgure l2 shows a cell 76 havlng a
rectangul~r secttonal ~rea at the surface of the pr1nt roll 72.
The direction of travel of the prtnt roll 72 ts destgnated by the
arrow numbered 75 and the ra~or and ~inor axes of the cell 76 are
designated m-m and ~ -~ respecttvely. The ~a~or axls m-m of the
rect~ngular cell 76 of Figure 12 ts oriented substantlally in the
machtne dtrectton. The mtnor ax1s ~ -m of the rectangular cell
76 ts or~ented substanttally ~n the cross-machtne dlrectton.
cell 76 of thts type wtll produce a prong 22 havtng a weak axts
oriented tn a d1rectton substantt~lly perpendtcular to the ~ach1ne
direct~on of the substr-te 2~ and the prong 22 wtll tend to
ortent substantt~lly tn the d1rectton of the weak axls of the
prong 22 t.e. the ~axtmum lateral pro~ection 38 of the prong 22
wlll tend to orient substanttalty tn the cross-mach~ne directton
of the substrate 2~. The ~xt~um lateral projectton 38 wtll
randomly ortent to~rd ~tther of the stdes of the prong 22
parallel to the ~aJor axts -m of the footprtnt ~owev~ by
sltghtl~ b1astng the prongs 22 the~ can be forced to ortent
toward a part~cular stde hr ~ore untfona array of prongs 22.
As ~nother nonltmtting example of a cel~ 76 whtch ~tll
produce a prong 22 havtng a ~e~k axts Ftgure 13 shows a cell 76
havtng an elltpttcal section-l area at the surface of the prtnt
roll 72. Agatn the ma~or and minor axes of the cell are
designated m-m and ~ -~ respectively. The major axis m-m of the
elliptical cell 76 of Ftgure 13 1s ortented substantially tn the
cross-machine direction. The minor axes m -m of the ellipttcal
cell ts oriented substantially in the machine direction. A cell
76 of this type wtll produce a prong 22 havtng a weak axts
oriented tn a direction substantially perpendicular to the

WO 94/274:61 PCTIUS94/05115
21 63331


cross-machine direction of the substr~te 2~ and the prong 22 will
tend to or1ent substantially 1n the d1rect10n of the weak axis of
the prong 22 l e the maximum lateral projectlon 38 will tend to
be oriented in the machine dlrect10n of the substrate 24 ~he
nlaxi~u0 l~teral projection 38 of the prong 22 will generally be
oriented 1n a direct10n oppos1te the dlrect10n of travel of the
substrate 2~ as a result of the blases 1nherent 1n the
~anufactur1ng process However by s11ghtly bt~s1ng the prongs 22
~s discussed hereinbefore they can easlly be forced to orlent ln
t;he directton of travel
As a th1rd non-l~mitlng example of a cell 76 ~h~ch ~
produce a prong 22 having a weak ~x~s Flgure lO shows a cell 76
which has a sectional ~re~ t the surface of the print roll 72
generally resembl1ng an equ11ateral triangle ~ith one slde of the
equilateral tr1angle generally par~llel to the mach1ne direct10n
of the print roll 72 Because the cell 76 of Flgure 10 is ~ three
slded flgure each of the three s1des belng equal ln length the
sell 76 ~lll h~ve three ~a~or ~xes (not shown) ~nd three ~lnor
axes (~ 2. ~ -~'3) The cell 76 wlll have ~ ma~or ax1s
~enerally p~rallel to each s1de of the equ11~ter~1 trlangle and
~inor axis generally perpendicular to each stde of the equilateral
1;riangle Therefore a cell 76 of this type will produce a prong
22 having a footpr1nt wlth three ma~or axis and three minor axes
correspond1ng to the three ma~or ~xls nd three minor ~xis of the
cell 76 The prong 22 wlll therefore have three weak axes and
lhe max1mum lateral pro~ect10n 38 of the prong 22 ~111 tend to
or1ent toward one of the three we~k ~xes An azimuthally ~ngled
prong 22 c~n be produced us1ng ~ cell 76 of th1s type dtsposed on
the pr1nt roll 72 such th-t the inor ~xes (~ 2.
nl -0 3) of the cell 76 sectional ~rea are each oriented 1n
direction other than the machine direction of the print roll 72
xuch as in Figure lO Because of the biases inherent in the
manufacturing process a prong produced from the cell 76 of Figure
10 will tend to be oriented toward the weak axis of the prong
which generally corresponds with minor axis m -m l of the cell 76
~ ithout being bound by any particular theory it 1s believed
t;hat the maximum lateral projection 38 of the prong 22 tends to

PCTlUS94/051 15
WO 94127461
2163331 ~


orient substant~ally in the direction of the ~eak axis of the
prong 22 1 e the direct10n of the ~inor axis m -m of the
footprlnt as a result of the shank 28 being unstable from a lack
of support from the base 26 ~long the s~des of the prong 22
parallel to the ma~or ~x1s ~-~ of the footprint
The mlnor ~xis m -- of a cell 76 may be or~ented in any
direction on the print roll 72 however ~s d~scussed above when
the x1nor axis m -m of a cell 76 ls or~ented in the ~achine
direction of the print roll 72 a prong produced us~ng th~t cell
76 will be gener~lly oriented in the ~achine direct10n of the
substrate 2~ i e not azimuthally angled Therefore
azimuthally angled prongs 22 ~ay be productJ using a cell 76
having an aspect ratio greater than about 1.1~ ith the minor
ax~s m -~ of the cell 76 oriented ~n a direct10n other than the
machine direction of the print roll ~2 To produce azi~uthally
angled prongs the mtnor axis m -m of the cetl 76 should be at an
angle greater th~n about I degree relative to the ~achine
dtrection of the pr1nt roll ~2, ~ll prefer~bl~ be ~t an ~ngle
greater than about 20 degrees relative to the ~ach1ne direction of
the pr~nt roll 72 ~ore preferably greater than about ~S dEgre~s
relative to the mach1ne d~rection of the print roll 72 and most
preferably greater than about 60 degrees relative to the ~achlne
direction of the pr~nt roll 72 In a preferred embodi~ent the
~inor axis m -~ of the cell ~6 ~ill be oriented ~bout 90 degrees
relative to the ~achine direction of the pr1nt roll 72 The
aspect ratio of the cell ~6 ~ill preferably be qreater than about
1 5 1; ~ore prefer~bly the aspect r~tio of the cell 76 ~111 be at
least ~bout 2~ nd ~ost prefer~bly the aspect ratto ~lll be ~t
least about 3:1
A prong 22 having an azimuthal angle may also be produced
using a cell 76 having a dominant area on one side of the machine
direction centerline of the cell 76 and having an aspect ratlo
greater than about 1 5 1 ~ithout being bound by any particular
theory it is believed that a prong 22 having a weak axis and a
bending axis and having a footprint with a dominant area will be
more likely to orient toward the side of the footprint having the
dominant area Therefore a cell 76 having an aspect ratio

WO 94/27461 PCTIUS94/05115
~ 2 1 6333 1


greater than about 1.5:1, havlng ~ dominant area and being
oriented on the pr1nt roll 72 such that the maJor axis ~-m of the
cell 76 generally corresponds w1th the mach1ne d1rectlon
centerline of the cell 76 wtll produce ~ prong 22 h~ving ~n
a~imuthal ~ngle of about 90 degrees relat~ve to the ~achine
direction The ma~or axis -- and the m~chine direct10n
centerline 65 correspond w1th e-ch other when they are gener~
oriented 1n the s-me d1rect10n 1 e are generilly parallel to
each other or gener~lly overlap each other
As used here1n the term ~m~chine d1rect10n centerllne- refers
to the centerl1ne of the cell in the ~achine dlrect~on The
machine direction centerllne of the cell can be determ~ned as
follows ~irst ~ 11ne 1s dr~wn par~llel to the machine
direction p~ssing through a po1nt on the perimeter of the cell
f~rthest out in the cross-mach1ne d~rect1cn on one slde of the
cell 76 A second ltne 1s drawn parallel to the mach1ne
directlon pass1ng through a point on the per1meter of the cell
f~rthest out 1n the cross-m-ch1ne direct10n on the other side of
the cell 76 These lines shown 1n F1gure 11, w111 be referred to
as the remote parallels 66 and w111 represent the boundar1es of
the~ width of the cell 76 taken perpendicular to the machine
direct10n As used herein the phrase w~dth of the cell 76 t~ken
perpenticul~r to the ~achine d1rection- refers to the distance
between the remote p~rallels 66 ~ e. the length of a line segment
drawn tetween nd perpendicular to the remote parallels 66 ~he
midpo1nt of tbe ~1dth of the cell taken perpend1cular to the
mach1ne d1rect10n ~s determ~ned and a llne 1s drawn par~llel to
the ~ach1ne d1rectton p~ss1ng through the mldpo1nt ~his llne
represents the mach1ne dlrection centerline 65 of the cell 76
As used herein the term dominant area~ refers to the port10n
of the sect~onal area of the cell 76 on one side of the machine
direction centerline 65 which is greater than the portion of the
sectional area of the cell 76 on the other side of the machine
direction centerline 65 If the sectional are- of the cell 76 is
symmetr1cal about the machine direction centerline 65 then the
cell will not have a dominant area such tS in ~igures 12 ~nd 13

PCT/US94/05115
WO 94/27461
2 1 6333 1 ~



As used herein the te m sect10nal area of the cell~ w111 refer to
the sect10nal ~rea of the cell 76 at the surface of the pr1nt roll
72 or other depos1t1ng member
As a non-l~m1t1ng example of a cell 76 hav1ng a dom1nant area
and having ~ ma~or axis m-m generally corresponding with the
machine d1rect10n centerline 65 of the cell 76 Figure ll sho~s a
cell 76 wh1ch has sectional re~ gener~lty of ~n 1sosceles
triangle w1th the base of the 1sosceles trlangle being generally
parallel to the ~achine d1rect10n and being longer than each of
the other s1des The m-ch1ne d1rect10n centerl1ne C5 of the cell
~6 has been determined by the ~ethod describet hereinabove and
the dominant are~ 69 of the cell 76 ts the port10n of the cell
sectional area wh1ch is to the r1ght of the machine direction
centerl1ne 65 The remote parallels 66 ~re posit10ned on e~ch
side of the machine d1rection centerl1ne 65 nd pass through the
po1nts on the per1meter of the cell farthest out 1n the
cross-m-chine direct10n ~he major axis ~-~ of the cell 76
generally corresponds ~ith the ~-chlne d1rection centerline 65 of
the cell 76 A prong 22 produced from a cell 76 of th1s type will
tend to or1ent toward the s1de of the footprlnt haY1ng the
dominant area 69 and w111 be or1ented generally 1n ~ direct1cn
having a vector component ~n the cross-machine d1rection of the
substr-te 2~ The ~spect rat10 of the cell 76 of Figure 11
prefer~bly ranges from about 1.5:1 to about 5 1 ~orc preferabl~
the aspect rat10 of the cell 76 wlll be about 2 1 to about ~ l
and tn a preferred embod1ment the cell 76 will have an aspect
rat10 of about 2 3:1
It 1s bel1eved that ~n az1muthally angled prong 22 ~ay
further be produced us1ng a cell 76 having at least two bottom
surface port10ns of unequal depth arranged such that the deepest
bottom surface portion is disposed somewhat near the perimeter of
the cell 76 i e adjacent to the wall of the cell 76 and the
cell 76 being disposed on the print roll 72 such that the deepest
bottom surface portion is disposed generally in a direction other
than the machine directlon
As a cell 76 of this type deposits molten thermally sensitive
material on to the substrate 24 the discrete amount of molten

PCT/US94/051 15
WO 94127461
~ 21 6333l



thermally sensitive materlal ~111 be centered or concentrated
over a point somewhat ad~acent to the perimeter or edge of the
footprlnt of the prong 22 rather than being concentrated over the
~iddle or center of the footpr1nt of the prong 22 The shank 28
of the prong 22 w~ll therefore be unstable from ~ lack of
support fro~ the b-se 26 at the edge of the footprlnt such that
the the forces of gravity ~111 act upon the dlstal end 29 and
engaglng means 30 of the prong 22 and dra~ the distal end 29 and
engaging neans 30 in a directlon ~h~ch generally corresponts wlth
the deepest bottom surf-ce portlon of the cell 76
As a non-llmitlng example Figure l5a shows a cell 76 having
two bottom surface portions 6~ ~igure lSb ts a cut-~ay view of
Figure l5a ~nd shows the cell 76 of Flgure 15a having one bottom
surface portton 6~ deeper than the other bottom surface portion
6~ ~he deepest bottom surf-ce portlon 6~ of thls cell 76 1s
disposed generally ad~acent to the wall of the cell 76 and the
cell 76 ~s ~rranged on the print roll 72 such that the deepest
bottom portlon 6~ of the cell ~6 1s dlsposed generally 1n the
cross-machlne dlrectlon It ls bel1eved that a cell 76 of thls
type ~111 p~od~ce a prong 22 that ~111 tend to orlent toward that
s~de of the prong 22 whlch generally corresponds ~lth the deepest
bottom surface portion 6~ of the cell 76 i e the ~axl~um lateral
pro~ectlon of the prong 22 ~111 orient generall~ ~n the
cross-machine dlrect~on
Preferabl~ the ratlo of the depth of the deepest botton
surface portlon 64 to the depth of the shallowest botto~ surface
portlon 64 ~111 be t least 1 5 1 and ~ore preferably ~ e ~t
least 2:1.
It should be understood that azimuthally angled prongs 22 ~a~
be produced by using a combinatlon of varlous methods
nonlimiting example of the use of combinations of methods is the
use of gravitational force and a pressure differential across the
plane of the substrate 24 in combination to impart an azimuthal
angle to the prongs 22 Another non-limiting example ls the use
of gravitational forces and a rotating severing means in
combination to impart an azimuthal angle to the prongs 22 A
thlrd non-limitlng example is the use of a pressure dlfferential

PCT/US94/05 1 15
WO 94/27461
2 1 6333 1 ~



across the p1ane of the substrate 2~ ~n combination with a prong
22 havlng an elltptical footprlnt wlth an aspect rat10 of 3~
Many other methods of lmpartlng an azlmuthal angle to the prongs
22 ~111 be apparent to one skilled ln the art as wlll the various
comblnatlons of ~ethods.
It should also be understood that the cells 76 can be
arranged on the prlnt roll 72 in any combinatlon 1.Q. the array
of cells 76 on the prlnt roll 72 ~ay be arranged such that all of
the cells 76 have elliptical secttonal areas and are d~sposed on
the print roll 72 with the minor axes of the cells 76 orlented ln
the same direction or in a variety of different directlons; or the
array of cells 76 on the pr~nt roll ~2 may compr~se a eombination
of cells ~6 some of ~h k h have clrcular sectional areas and some
of whlch have triangular sectional areas; or the array of cells 76
on the prlnt roll 72 may comprlse any other comblnatlon of
sectlonal areas or cell depths oriented in any combination of
directions on the print roll ~2. There are an unlimited number of
possible combinations and all posslble conblnations are tntended
to be covered in the appended Clatms.
ILLUSTRA~IVE AR~ICLE OF USE
An illustratlve and nonllmittng example of the usage of the
fastening syste~ 120 of the present invention in ~n article of
manufacture fol~c~s ant is lllustr~ted in Figure 6. Mechan~cal
fastening s~stems h-ve been advantageousl~ used in disposable
absorbent arttcles as dlsclosed ln U.S. Patent No. ~ 8~6 815
flled on December 18 1987 ln the na~e of Scr~pps wh1ch
appllcatlon ls lncorporated hereln by reference for the purpose of
show)ng a diaper 110 structure and the advantageous ~tlll~atlon of
mechanlcal fastenlng systems 20 ln such diaper 120 structures.
It ls known for example that mechanical fastening systems
are less easily contamlnated by olls and powders than are adhesive
tape fastenlng systems and further may be easlly reused. All of
these features provide advantages when appl1ed to a disposable
diaper intended for use on an infant. Also a refastenable
fastening system provides the advantage that the infant may be
checked to see if soiling of the disposable diaper has occurred
during the wearing period.

WO 9~/~7461 PCTIU594/05115



Referring to ~igure 6 there ls shown a disposable di-per llO
1ntended to be worn about the lower torso by an 1nfant. As used
hereln the ter~ ~disposable ~bsorbent ~rt1cle~ refers to
garment generally worn by 1nfants or 1ncontinent persons and wh1ch
~~s drawn between the legs fastened about the waist of the wearer
and 1ntended to be dlscarded after a slngle use and not to be
~aundered or restored. A d1sposable diaper~ 1s a partlcular
disposable ~rt1cle 1ntended and scaled to be worn by an ~nfant.
A preferred diaper llO compr1ses a 11qu1d perv~ous topsheet
il2 a 11quid 1mpervious backsheet 116 ~nd an ~bsorbent core 118
intermediate the topsheet 112 and backsheet 116. The topsheet 112
and backsheet 116 are at least partially peripherally ~o1ned to
ensure the core 118 is held in pos1t10n. The diaper 110 elements
~ay be assembled 1n a variety of conf1gurat~ons well known to one
sk111ed in the art wlth preferred conf1guratlons be1ng generally
described 1n U.S. Patent No. 3 860 003 issued January l4 1975 to
~uell and U.S. Patent No. 4 699 622 1ssued October 13 1987 to
loussant et al. which patents are incorporated here1n by
reference for the purpose of d1sclos1ng a part1cul~rly preferred
d1aper 110 configur~t10n.
The topsheet 112 and backsheet 116 of the d1aper 110 ~re
~enerally coextenslve and at least partially per1pherally ~o1ned
together as noted above. Joining of the topsheet 112 and
backsheet 116 ay be ccompl~shed by a hot-melt dhes1ve such as
~dhes1~e ~o. I258 manufactured by the H.B. Fuller Company of
Vadna1s Heights Hinnesot~ 55110. The ~bsorbent core ll8 h~s
~ength and w1dth d1mens10ns generally less than that of the
topsheet 112 and backsheet ll6. The core ll8 1s 1nterposed
between the topsheet 112 and backsheet 116 in f1xed relat10nship.
The diaper 110 periphery comprises oppositely disposed first
and second ends 122 and 124. The diaper 110 has a first wa1st
portion 142 and a second waist portion 144 extending respectively
from the first end 122 and second end 124 of the diaper 110
periphery towards the lateral centerline of the diaper 110 a
distance of about one-fifth to about one-third the length of the
diaper 110. The waist portions 142 and 144 comprise those
portions of the diaper 110 which when worn encircle the waist of

PCT/US94/05115
WO 94/27461
21 63331 ~


the wearer and are generally t the highest elevatton of the
d1aper 110 when the wearer ls 1n the standing posit1On. ~he
crotch 146 of the dlaper l10 1s that portlon of the diaper ll0
disposed between the flrst and second w~st port1Ons 1~2 and 1~4
and wh1ch when worn is posit1Oned between the legs of the wearer.
The ~bsorbent 3c~re- ls any ~eans for absorbing and retaining
liqu~d body exudates. ~he bsorbent core 118 ls generally
compress1ble conformable nd nonirritat1ng to the skin of the
~e~rer. A preferred core 118 has f1rst and second opposed faces
and ~ay if des1red be further encased by t1ssue layers. One
opposed face of the core 118 is oriented towards the topsheet 112
and the other opposed face ts orlented towards the backsheet 116.
The absorbent core 118 is supertmposed on the backsheet II6
and preferably ~oined thereto by any means well known 1n the art
such as adhes1ve bond1ng. In a part1cularly preferred embodiment
adhes1ve bonding which ~oins the core 118 to the b~ckshcct 116 1s
acco~pl1shed by apply1ng adhes1ve 1n the for~ of a sp1ral. The
backsheet 116 1s 1mpervious to 11qu1ds and prevents 11qu1ds
absorbed by and conta1ned 1n the absorbent core 118 fro~ wettlng
undergar~ents clothtng bedding ~nd any other ob~ects wh1ch
contact the diaper II0. As used herein the ter ~backsheet~
refers to ~ny barrier disposed outwardly of the core 118 as the
di~per ll0 is worn ~nd wh1ch cont~1ns absorbed 11qulds with1n the
diaper ll0. Preferably the backsheet 116 1s a pol~olefinic fll~
of about 0.025 to about 0.030 mill1meters (0.001-0.0012 lnches) 1n
th1ckness. A polyethylene ~ s part1cularl~ preferred with a
su1table fll~ be1nq ~anufactured by Tredegar Industr ks of
Rich~ond V1rg1n1a 23225 and the Clopay Corporat1On of
Clncinnati Oh1O ~5202. If des1red the backsheet 116 ~ay be
embossed or 0atte finishet to provide a more clothl1ke appearance
or be provided wlth passages to permit escape of vapors.
The topsheet Il2 is compllant tactitely pleasing and
nonirritating to the wearer s skin. The topsheet 112 prevents
contact of the absorbent core 118 and liquids thereln with the
skin of the wearer. The topsheet 112 is liquid pervious
permitting liquids to readily penetrate therethrough. As used
herein the term ~topsheet~ refers to any l~quid pervious facing

WO 94/27461 2 1 6 3 3 3 1 PCTIUS94/0511

53

h1ch contacts the skin of the ~earer wh11e the diaper 110 ~s
be1ng ~orn and prevents the core 118 from contact~ng the skln of
the wearer. The topsheet 112 may be made of woven nonwoven
xpunbonded or c-rded a~ter1~1s. A preferred topsheet 112 1s
carded and thermally bonded by ~eans to those skilled in the
nonwoven fabrlcs art. ~ part1cularly preferred topsheet 112 has a
we19ht of about 21 to about 24 grams per square neter a 1ni~u~
dry tens11e strength of about 138 grams per centt-eter 1n the
~ach1ne d1rection and a wet tens11e strength of at least about 80
grams per centlmeter 1n the cross-nach1ne d1rect10n.
The diaper 110 is prov1ded wlth a fasten1ng system 120 and
receiving surface 153 for nalnta1ning the f1rst ~a1st portion 1~2
and second ~a1st portlon 1 U 1n an overlapp~ng configuration when
;he d1aper llO 1s worn so that the d1~per llO 1s secured to the
wearer. Thus the d1aper llO 1s fltted to the ~earer and a s1de
closure 1s formed ~hen the fasten1ng system 120 1s secured to the
rece1v1ng surface 153.
The fasten1ng syste~ 120 should res1st the separat10n forces
~h1ch occur dur1ng the ~ear1ng per10d. The tere separat10n
forces~ refers to forces act1ng on the fasten1ng syste~ 120 and
receiving surfacc l53 whlch tend to cause separat10n release or
removal of the fastening s~stem 120 from the receiving surface
153. Separation forces include both shear and peet forces. The
1en~ shear force~ refers to distribut1ve forces acting generall~
l;angent1al to the rece1v1ng surface 153 and ~hlch ~ay be thought
of as be1ng generally parallel to the plane of the substrate of
t;he fastenlng syste~ 120. The tenr ~peel forces- refers to
distrlbut1ve forces act1ng 1n the generally long1tud1nal
d1rect10n and perpend kular to the plane of the rece1Y1ng surface
153 and fasten1ng system 120 substrates.
Shear forces are measured by tens11e pulling of the fastenlng
system 120 and receiving surface 153 in opposite directlons
generally parallel to the planes of the respective substrates.
The method used to determine the res1stance of a fastenlng system
]20 and recelvlng surface 153 to shear forces ls more fully set
forth 1n U.S. Patent No. 4 699 622 issued October 13 198~ to
Toussant et al. which patent is incorporated herein by reference.

WO 94/27461 PCT/US94/05115
2 1 6333 1
s~

Peel forces are ~easured by tenslle pulllng of the fasten1ng
system 120 from the receiving surface 153 at an included angle of
about 135 ~he ~ethod used to determine the reslstance of a
fastenlng syste~ 120 and recelvlng surface 153 to peel forces ls
~ore fully set forth ln U S Patent No ~ 846 815 filed November
18 198~ ln the name of Scrlpps whlch applicatlon ls incorporated
herein by reference for the purpose of descr~blng the measurement
of peel forces
Separation forces are typlcally generated by ~ove~ents of the
~earer or by the wearer trylng to unfasten the dlaper 110
Generally an lnfant should not be able to unfasten or renove a
diaper 110 the lnfant ls wearlng nor should the diaper 110 co~e
unfastened ln the presence of ordinary separatlon forces ~hich
occur durlng nor~al wearlng However an adult should be able to
remove the diaper 110 to change lt when solled or check to see lf
solllng has Occulr~d 6enerally the fastenlng system 120 and
recelvlng surface 153 should reslst a peel force of at least 200
grams prefer~bly at least about 500 grams and ~ore prefer~bly
at least ~bout 700 grams Furthermore the fastenlng systen 120
and recelv~ng surf-ce 153 should reslst a she~r force of at least
500 gra~s preferabl~ at least about ~50 gra~s and ~ore
preferably at least ~bout 1 000 gra~s
The recelving surface 153 ~ay be disposed in a first poslt~on
anywhere on the diaper 110 so long as the recelvlng surface 153
engages the fastenlng ~eans to matntaln the first and second walst
portlons 1~ ~n an overlapping configur~tion For example the
receiving surface 153 ma~ be disposed on the outslde surface of
the second walst portion lU on the inside surface of the first
waist port~on 1~2 or ~ny other pos~t~on on the d~per 110 on
which it ls disposed so as to engage with the fastentng system
120 The receiving surface 153 may be integral a discrete
element ~oined to the diaper 110, or a slngle piece of ~terial
that ls nelther divided or discontinuous with an element of the
diaper 110 such as the topsheet 112 or backsheet 116
~ hile the receiving surface 153 may assume various sizes and
shapes the receiving surface 153 preferably comprises one or more
integral patches positioned across the outslde surface of the

WO 94/27461 2 ~ 63 33 I PCT/US94105115
.




second waist portton l44 to llo~ for maximum flt d~ust ent at
the walst of the wearer As lllustrated 1n Flgure 6 the
receiving surface l53 is preferably an elongate rectangularly
shaped tntegral member secured to the outer surface of the second
~alst port1On l U
A sult~ble receiv1nq surf-ce 153 is a nGn~v~n fabrtc ts
stltchbonded or any other type of fiber or toop m~terial ~ell
known ln the art The receiYing surf-ce 153 may be anufactured
from ~ varlety of matertals ~hlch provlde flber elements and
preferably loops capable of being intercepted and retatned by the
engaglng means Suitable materlals include nylon polyester
polypropylene ~nd combinations of the forego~ng A suitable
rec~iving surface 153 comprlses a number of f~ber loops pro~ectlng
from a woven and ts commercially avallable as Scotchmate brand
nylon woven loop Ho FJ340l sold by the ~innesota ~in~ng and
~3nufactur1ng Company of St P~ul Minnesota Another sultable
receiving surface 153 compr1ses ~ tricot having a plurality of
nylon fllament loops pro~ecttng from a nylon backing and 1s
commerci~lly avallable from Gll h rd Mtlls of Greensboro North
Carol~n~ ~nd destgn-ted 611ford Ho 16110 A particularl~
preferred recetvtng surface ts stitchbonded loop materlal sold by
tle Hill~ken Company of Spartanburg South Carolina under Number
970026
The fastentng system 120 ls 1ntended to engage the
complementary recelv1ng surface 153 to provlde a secure fit for
the dlaper llO rhe fastening system 120 may compr1se ~ny of the
~ell kno~n conflgur~ttons utll1~ed for achlev1ng a s~de closure on
a dlsposable dtaper llO The fasten1ng system l20 substrate ts
~oined to the dlaper llO in spaced relattonshtp from the receiving
means 153 As shown on Figure 6 the fastentng syste~ 120 1s
preferably disposed on both the first and second tonqitudinal
sides of the dtaper 110. A preferred configuration for the
fastening system 120 minimi2es any potential contact bet~een the
prongs of the fastening system 120 and the skin of the wearer A
preferred fastening system 120 dispositlon ts a Y-shaped tape
arrangement described in detail in U S Patent No 3 848 594
issued November 19 1974 to Buell An alternatlvel~ preferred

PCT/US94/05115
WO 94/27461
21 63331 ~
56

fastenlng syste~ 120 arrangement 1s descrlbed ~n detail ln U S
Patent No ~ 699 622 lssued October 13 1987 to Toussant et al
both of wh1ch patents are lncorporated herein by reference for the
purpose of 111ustrating various place~ents of the fastening system
l20 on the d1spos~ble diaper 110. A particularly preferred
fastening system 120 dispos1tion ~s a s~ngle tape tab attached to
only one s1de of the dl~per thls type of ~astening syste~
arrangement ts ~ell known in the dtsposable dlaper art and
non-11mlting example of th1s type of fastenlng s~ste arrangement
1s descrlbed ~n U S Patent No ~ 8~6 815 lssued Jul~ 1l 1989 to
Scripps whlch ls lncorporated hereln by reference
~ he fasten1ng system 120 of flgure 6 has a manufacturer s end
156 and n oppositely dlsposed user s end 158 The ~anufacturer s
end 156 ls ~olned to the diaper 110, preferably ln ~uxtapos~tlon
with the flrst ~alst portlon 1~2 The user s end 158 ls the free
end ~nd 1s secured to the recelv~ng surface 153 when the dlaper
110 ls secured to the wearer
After the di~per 110 ls fltted about the waist of the ~earer
the user s end 158 of the fasten1ng system 120 1s rel~asably
secured to the receivtng surf~ce 153 and preferabl~ posltloned on
the second walst portlon 1~4 thereby causlng the dlaper 110 to
encircle the waist of the wearer The diaper 110 has now effected
~ side closure The prongs (not shown) extend fro the f~sten1ng
system 120 of the user s end 158 so that the prong eng-ging means
lntercept the str~nds of the rece1vlng surface 153
A fasten~ng syste~ 120 nd complementary recelvlng surface
153 wh~ch proYldes a reslstance to peel forces in excess of 700
grams and a reslstance to shear forces ln excess of l OCO grams
may be constructed as foltows ~ccording to the spec~f1c par~meters
of the fastening system 120 set forth in the aforementioned
~Process of Manufacture ~ The complementary recelving surface 153
used ln con~unct~on with the fastening syste~ 120 is the
aforementioned Mill1ken Company No 970026 stitchbonded loop
fabric
The fastening system 120 is at least about 2 5~ centimeters
(I inch) ln width and may be of any length which provides a
convenient user s end 158 with a length of at least about 3 5

WO 94/27461 PCTIUS94/05115
~ 2 1 6333 1
5~

centtmeters (l.~ lnches) be1ng preferred. The arr~y of the prongs
of f~sten1ng system 120 compr1ses ~tr1x h~v1ng ~bout 26 prongs
per squ~re cent1meter (169 prongs per squ~re 1nch). The prongs
~re preferentl~lly or1ented 1n subst~nt1~11y the s~me directlon
~nd are preferent1~11y orlented to~ard the ~anuf~cturer s end 156
of the fastening tape of the f~sten1ng t~pe when the disposable
art1cle 1s 1n use.
In use the d1aper 110 1s applled to the ~e~rer b~
pos1t10ning the f1rst wa1st port10n 1~2 around the ~earer s b~ck
~nd dr~1ng the rema~nder of the d1~per 110 between the legs of
the we~rer so that the second wa1st portion 1 U ts d~sposed across
the front of the wearer. The user s ends 158 of the fasten1ng
system 120 are then secured to the rece1ving surface l53 on the
outs1de surf~ce of the second w~1st port10n l U to for~ ~ side
closure.
~ hile part1cular embodiments of the present invent~on h~ve
been 111ustrated and descr1bed 1t would be obv~ous to those
sk111ed in the art th~t var10us other changes ~nd ~od1f1cat10ns
can be m~de w1thout dep~rt1ng from the sp1r1t ~nd scope of the
1nventlon. It ts therefore 1ntended to cover 1n the rpe-.ded
cl~lms ~ll such changes ~nd ~od1fic~t10ns th~t ~re ~tthin the
scope of th1s 1nvent10n.

Representative Drawing