A composite core material and methods for making same are disclosed herein. The composite core material comprises mineral filler discontinuous portions disposed in a continuous encapsulating resin. Further, the method for forming a composite core material comprises the steps of forming a mixture comprising mineral filler, an encapsulating prepolymer, and a polymerization catalyst; disposing the mixture onto a moving belt; and polymerizing said encapsulating prepolymer to form a composite core material comprising mineral filler discontinuous portions disposed in a continuous encapsulating resin.

A composite core material and methods for making same are disclosed herein. The composite core material comprises mineral filler discontinuous portions disposed in a continuous encapsulating resin. Further, the method for forming a composite core material comprises the steps of forming a mixture comprising mineral filler, an encapsulating prepolymer, and a polymerization catalyst; disposing the mixture onto a moving belt; and polymerizing said encapsulating prepolymer to form a composite core material comprising mineral filler discontinuous portions disposed in a continuous encapsulating resin.

A method of molding resin on a flexible substrate includes forming discrete regions of resin and forcing resin of at least some of the regions into molding cavities to form a respective array of resin projections extending from a resin base of the regions. Forming the discrete regions of resin includes depositing molten resin directly onto either the substrate or a surface in which the cavities are defined. The resin is deposited as the substrate moves in a processing direction, and the resin is deposited by resin sources spaced from each other along the processing direction.

A method for assembling an assembly comprising a tape (100) of retaining elements and a substrate (200), said method comprising the following steps: a step of forming a tape of retaining elements by dispensing a molding material into a molding device (1), so as to form a tape (100) of retaining elements comprising a base (51) presenting a bottom face (511) and a top face (512), the top face (511) of the base (51) being provided with retaining elements; and a step of applying a substrate (200) against the bottom face (511) of the base (51) prior to said bottom face (512) of the base (51) solidifying in such a manner as to cause the substrate (200) to penetrate at least in part beyond a plane defined by the bottom face (511) of the base (51) of the tape (100).

A method for assembling an assembly comprising a tape (100) of retaining elements and a substrate (200), said method comprising the following steps: a step of forming a tape of retaining elements by dispensing a molding material into a molding device (1), so as to form a tape (100) of retaining elements comprising a base (51) presenting a bottom face (511) and a top face (512), the top face (511) of the base (51) being provided with retaining elements; and a step of applying a substrate (200) against the bottom face (511) of the base (51) prior to said bottom face (512) of the base (51) solidifying in such a manner as to cause the substrate (200) to penetrate at least in part beyond a plane defined by the bottom face (511) of the base (51) of the tape (100).

In embodiments, a flexible mat forming system includes a rotating drum having a plurality of mold cavities; a hopper that receives a hardenable paste and deposits the hardenable paste into the mold cavities as the drum rotates relative to the hopper; and a sheet of mesh material that is fed between the hopper and the mold cavities facing the hopper. The hopper includes a plurality of side walls and a bottom panel having an opening, wherein the plurality of walls and the bottom panel define an interior chamber; and an auger rotatably mounted in the interior chamber and having a plurality of radially extending protrusions along a length thereof, the radially extending protrusions including angled surfaces to displace the material received in the interior chamber along a length of the interior chamber to fall through the opening into the mold cavities.

In embodiments, a flexible mat forming system includes a rotating drum having a plurality of mold cavities; a hopper that receives a hardenable paste and deposits the hardenable paste into the mold cavities as the drum rotates relative to the hopper; and a sheet of mesh material that is fed between the hopper and the mold cavities facing the hopper. The hopper includes a plurality of side walls and a bottom panel having an opening, wherein the plurality of walls and the bottom panel define an interior chamber; and an auger rotatably mounted in the interior chamber and having a plurality of radially extending protrusions along a length thereof, the radially extending protrusions including angled surfaces to displace the material received in the interior chamber along a length of the interior chamber to fall through the opening into the mold cavities.

A molding apparatus (10) for forming a retaining device. The molding apparatus (10) comprises a molding strip (12) and a molding support (24). The molding strip (12) has an inside face (14), an outside face (16), and a plurality of through cavities (18) extending from the outside face (16) to the inside face (14), the molding strip (12) extending in a longitudinal direction (X) and presenting both a transverse direction (Y) perpendicular to the longitudinal direction (X), and also a height direction (Z) perpendicular to the longitudinal direction (X) and to the transverse direction (Y). The inside face (14) is configured to press against a molding face (26) of the molding support (24), wherein the inside face (14) of the molding strip (12) and/or the molding face (26) of the molding support (24) includes an array of passages, the array of passages forming vents and connecting together the cavities (18) when the molding strip (12) is pressed against the molding support (24).

A molding apparatus (10) for forming a retaining device. The molding apparatus (10) comprises a molding strip (12) and a molding support (24). The molding strip (12) has an inside face (14), an outside face (16), and a plurality of through cavities (18) extending from the outside face (16) to the inside face (14), the molding strip (12) extending in a longitudinal direction (X) and presenting both a transverse direction (Y) perpendicular to the longitudinal direction (X), and also a height direction (Z) perpendicular to the longitudinal direction (X) and to the transverse direction (Y). The inside face (14) is configured to press against a molding face (26) of the molding support (24), wherein the inside face (14) of the molding strip (12) and/or the molding face (26) of the molding support (24) includes an array of passages, the array of passages forming vents and connecting together the cavities (18) when the molding strip (12) is pressed against the molding support (24).

A molding apparatus (10) for forming a retaining device. The molding apparatus (10) comprises a molding strip (12) and a molding support (24). The molding strip (12) has an inside face (14), an outside face (16), and a plurality of through cavities (18) extending from the outside face (16) to the inside face (14), the molding strip (12) extending in a longitudinal direction (X) and presenting both a transverse direction (Y) perpendicular to the longitudinal direction (X), and also a height direction (Z) perpendicular to the longitudinal direction (X) and to the transverse direction (Y). The inside face (14) is configured to press against a molding face (26) of the molding support (24), wherein the inside face (14) of the molding strip (12) and/or the molding face (26) of the molding support (24) includes an array of passages, the array of passages forming vents and connecting together the cavities (18) when the molding strip (12) is pressed against the molding support (24).