Methods for producing a high aspect ratio nanostructured thermoplastic polymer foil, or a nanostructured thermoplastic polymer coating on a carrier foil, including at least one high aspect ratio nanostructured surface area are described herein. A method may include providing an extrusion coating roller for an industrial polymer extrusion coating process using a thermoplastic material, applying a high aspect ratio nanostructured surface on the extrusion coating roller thereby forming a high aspect ratio nanostructured extrusion coating roller, maintaining the temperature of the high aspect ratio nanostructured extrusion coating roller below the solidification temperature of the thermoplastic material, moving a carrier foil between the rotating high aspect ratio nanostructured extrusion coating roller and a rotating counter pressure roller, and continuously applying a melt of the thermoplastic material between the moving carrier foil and the rotating high aspect ratio nanostructured extrusion roller.

A laminated touch fastener is made in a continuous process on a mold roll. Flowable resin is pressed against the mold roll in limited areas to form projections extending from resin layers that are laminated to a flexible substrate while carried on the mold roll. In one example a continuous channel about the mold roll is positioned such that the resin at least partially fills the channel as the layers are formed, thereby forming in the channel a raised portion in which the resin layer is of a greater thickness than at a point between the projections and the raised portion. In another example, grooves in the mold roll receive ribs of a pressure applicator during forming of the layers, the ribs blocking lateral flow of the resin to form a desired edge profile.

Aspects of the present disclosure relate to methods and apparatuses for manufacturing absorbent articles, wherein discrete zones of protrusions may be formed on a substrate. In some configurations, the protrusions may be formed as hooks. When forming the discrete zones of protrusions, localized speed variances may be imparted to the advancing substrate to ensure the adequate time to form the protrusions is provided. As such, protrusions may be formed on portions of the substrate that have been temporarily stopped or slowed to relatively slow speeds. The substrates with zones of protrusions may then be incorporated into products, such as assembled absorbent articles, so as to place the protrusions in desired positions on the absorbent articles. As such, the methods and apparatuses herein allow for the use of hook forming techniques on substrates in article manufacturing processes that provide flexibility in such configurations without sacrificing desired manufacturing speeds.

Aspects of the present disclosure relate to methods and apparatuses for manufacturing absorbent articles, wherein discrete zones of protrusions may be formed on a substrate. In some configurations, the protrusions may be formed as hooks. When forming the discrete zones of protrusions, localized speed variances may be imparted to the advancing substrate to ensure the adequate time to form the protrusions is provided. As such, protrusions may be formed on portions of the substrate that have been temporarily stopped or slowed to relatively slow speeds. The substrates with zones of protrusions may then be incorporated into products, such as assembled absorbent articles, so as to place the protrusions in desired positions on the absorbent articles. As such, the methods and apparatuses herein allow for the use of hook forming techniques on substrates in article manufacturing processes that provide flexibility in such configurations without sacrificing desired manufacturing speeds.

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 method of forming deformations in a nonwoven web includes the steps of: a) providing a precursor nonwoven web; b) providing a pair of forming members which include: a first forming member having a surface comprising a plurality of discrete, spaced apart male forming elements; and a second forming member having a surface comprising a plurality of recesses in the second forming member, wherein the recesses are aligned and configured to receive the male forming elements therein, wherein the recesses have a plan view periphery that is larger than, and may completely surround, the plan view periphery of the male elements; and c) mechanically deforming the precursor nonwoven web with the forming members by placing the precursor nonwoven web between the forming members. The method forms a nonwoven web having a generally planar first region and a plurality of discrete deformations. The deformations form protrusions that extend outward from the first surface of the nonwoven web and a base opening adjacent to the second surface of the nonwoven web. The maximum interior width of the cap portion of the protrusions is wider than the width of the base opening.

Sheet having fastening elements, comprising a base strip made of thermoplastic material and at least one element made from the strip, the element consisting of a stem extending in a transverse, in particular vertical, direction to the plane of the base strip, and having a cross section which is substantially uniform or decreases from the base strip towards the apex of the stem, in particular as far as the apex of the stem, and a part forming a head which protrudes laterally from the apex of the stem.

A method of forming a retaining device with hooks, wherein: a molding strip is provided that presents an inside face and an outside face, and that has a plurality of cavities, each cavity defining a stem extending from the outside face towards the inside face and including an end forming a head that extends from the stem towards the inside face of the molding strip; the molding strip is positioned on rotary drive means, the inside face of the molding strip being arranged to bear against the drive means; and molding material is dispensed against the outside face of the molding strip.

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).

This manufacturing method of a molded surface fastener involves a primary molding step for forming a primary molded body and a secondary molding step for compressing a provisional element of the primary molded body while heating the same. A molding apparatus is provided with a mold member comprising multiple penetration holes and multiple concave portions, whereof each penetration hole communicates to at least one concave portion; in the primary molding step, the molding apparatus is used to form a primary molded body comprising a provisional element having a primary stem portion and a pawl portion is formed from the protruded portion by compressing the provisional element. By this means, it is possible to stably manufacture a molded surface fastener that has an engaging element comprising a pawl portion that projects from the outer peripheral edge of an engaging head portion.