US4735753A — Method of making a fastener

Claim 1

Independent Claim 178 words

The method of precision-forming a fastener at a predetermined location on one side of a sheet of porous substrate material, wherein the fastener is one part of a two-part fastenable combination, which method comprises applying a premeasured quantity of plastic working material to said one side at said location, establishng an enclosed volume adjacent to and surrounding said location and said plastic working material on said one side, said enclosed volume being completed by circumferentially continous annular sealing compression of said substrate material against a reaction anvil on the other side of said substrate material, then compressionally deforming the premeasured working material against said one surface and against anvil reaction by direct vibratory excitation of the working material to melt the same and force its impregnation of substrate pores within the compressionally sealed annulus, the premeasured quantity of working material being greater than that required for such porous impregnation, whereby excess plastic working material remains at said one surface after local porous impregnation of the substrate, and die-forming the fastener from excess plastic material within the enclosed volume.

Claim 2

Independent Claim 178 words

The method of precision-forming a fastener at a predetermined location on one side of a sheet of porous substrate material, wherein the fastener is one part of a two-part fastenable combination, which method comprises applying a premeasured quantity of plastic working material to said one side at said location, establishng an enclosed volume adjacent to and surrounding said location and said plastic working material on said one side, said enclosed volume being completed by circumferentially continous annular sealing compression of said substrate material against a reaction anvil on the other side of said substrate material, then compressionally deforming the premeasured working material against said one surface and against anvil reaction by direct vibratory excitation of the working material to melt the same and force its impregnation of substrate pores within the compressionally sealed annulus, the premeasured quantity of working material being greater than that required for such porous impregnation, whereby excess plastic working material remains at said one surface after local porous impregnation of the substrate, and die-forming the fastener from excess plastic material within the enclosed volume.

Claim 3

Independent Claim 265 words

The method of using a cylinrdical ram to precision-form an outwardly open cupped fastener at a predetermined location on one side of a sheet of porous substrate material, which method comprises applying a premeasured quantity of plastic working material to said one side at said location, establishing an enclosed volume adjacent to and surrounding said location and said plastic working material on said one side, said enclosed volume being completed in part (a) by circumferentially continuous annular sealing compression of said substrate material against a reaction anvil on the other side of said substrate material, the sealed annulus defining an inner uncompressed area of substrate material exceeding the sectional area of the ram, said enclosed volume being further completed (b) by circumferentially continuously sealed sliding engagement to the cylindrical surface of the ram on an axis normal to the substrate material at said location, then compressionally defomring the premeasured working material aganist said one surface and against anvil reaction by direct vibratory driven contact of the inner end of the ram with the working material to melt the same and force its impregnation of substrate pores within the compressionally sealed annulus, the premeasured quantity of working material being greater than that required for such porous impregnation, whereby excess plastic working material remains at said one surface after local porous impregnation of the substrate, and die-forming the fastner from excess plastic material within the enclosed volume by inwardly displacing and vibrationally driving the ram to the extend achieving an outward dispalcement of working material into circumferentially continuous axial overlap of the inner end of the ram.

Claim 4

Independent Claim 265 words

The method of using a cylinrdical ram to precision-form an outwardly open cupped fastener at a predetermined location on one side of a sheet of porous substrate material, which method comprises applying a premeasured quantity of plastic working material to said one side at said location, establishing an enclosed volume adjacent to and surrounding said location and said plastic working material on said one side, said enclosed volume being completed in part (a) by circumferentially continuous annular sealing compression of said substrate material against a reaction anvil on the other side of said substrate material, the sealed annulus defining an inner uncompressed area of substrate material exceeding the sectional area of the ram, said enclosed volume being further completed (b) by circumferentially continuously sealed sliding engagement to the cylindrical surface of the ram on an axis normal to the substrate material at said location, then compressionally defomring the premeasured working material aganist said one surface and against anvil reaction by direct vibratory driven contact of the inner end of the ram with the working material to melt the same and force its impregnation of substrate pores within the compressionally sealed annulus, the premeasured quantity of working material being greater than that required for such porous impregnation, whereby excess plastic working material remains at said one surface after local porous impregnation of the substrate, and die-forming the fastner from excess plastic material within the enclosed volume by inwardly displacing and vibrationally driving the ram to the extend achieving an outward dispalcement of working material into circumferentially continuous axial overlap of the inner end of the ram.

Claim 5

Dependent Claim 16 words

The method of claim 1 or claim 2, in which the fastener is a snap-fastener stud.

Claim 6

Dependent Claim 16 words

The method of claim 1 or claim 2, in which the fastener is a snap-fastener socket.

Claim 7

Dependent Claim 30 words

The method of claim 1 or claim 2, in which the compressive deformation is by ultrasonic modulation of a continuous force applied normal to the substrate and to the anvil.

Claim 8

Dependent Claim 70 words

The method of claim 1, in which said fastener is characterized by a central bore in a generally cylindrical annulus upstanding from the porous impregnation, in which a compression applicator is selected for local generally cylindrical definition of the profile of said bore, and in which an annulur forming die is selected for definition of said generally cylindrical annulus in conjunction with displacement of said applicator within said forming die.

Claim 9

Dependent Claim 26 words

The method of claim 1, in which the compression applicator is selected for a circumferentially continuous convex bulbous tip-end contour, for socket-bore definition of said complimentary.

Claim 10

Dependent Claim 20 words

The method of claim 5, in which the ultrasonic modulation is terminated prior to termination of the applied continuous force.

Claim 11

Dependent Claim 40 words

The method of claim 1 or claim 2, in which said premeasured quantity is the product of shearing a predetermined length of plastic rod, said shearing being in an automated cycle synchronized with an automated cycle of compression-deformation and die-forming.

Claim 12

Dependent Claim 19 words

The method of claim 9, in which the plastic rod is preheated to softening temperature immediately prior to shearing.

Claim 13

Dependent Claim 34 words

The method of claim 1 or claim 2, in which the porous impregnation and the die-forming of excess plastic material are accomplished in the course of a single and continuous application of compressive energy.

Claim 14

Dependent Claim 17 words

The method of claim 1 or claim 2, in which the porous substrate material is a fabric.

Claim 15

Dependent Claim 17 words

The method of claim 1 or claim 2, in which the porous substrate is a woven fabric.

Claim 16

Dependent Claim 37 words

The method of claim 1 or claim 2, in which the porous substrate material is a tape, and in which the formed fastener is one of a plurality in similarly formed and spaced array along the tape.

Claim 17

Dependent Claim 48 words

The method of claim 1 or claim 2, in whch the reaction anvil is selected for flat-surface application to the opposite surface of the substrate material, whereby the product of the method is characterized by a consolidated impregnation which terminates flush with the opposite surface of the substrate.

Claim 18

Dependent Claim 66 words

The method of claim 1 or claim 2, in which the reaction anvil is selected for flat-surface peripherally continuous application to the opposite surface of the substrate and in which, within the flat-surfaced periphery, the anvil has a cavity, whereby to form at the opposite surface at least a raised shape conforming to the cavity and integrally consolidated with the impregnation and with the formed fastener.

Claim 19

Dependent Claim 84 words

The method of claim 1 or claim 2, in which the reaction anvil is selected for peripherally continuous land application to the opposite surface of the substrate, and in which plural spaced fasteners are sequentially formed by the same die-forming and anvil components, and in which within the land, the anvil has a cavity, whereby to form at the opposite surface and at each fastener location a raised shape conforming to the cavity and integrally consolidated with the impregnation and with the formed fastener.

Claim 20

Dependent Claim 23 words

The method of claim 16 or claim 17, in which the anvil cavity is characterized by a wall having an intaglio formation therein.

Claim 21

Dependent Claim 23 words

The method of claim 16 or claim 17, in which the anvil cavity is characterized by a wall having a relief formation therein.

Claim 22

Dependent Claim 43 words

The method of claim 1 or claim 2, in which the reaction anvil is selected for peripherally continuous land application to the opposite surface of the substrate, and in which plural spaced fasteners are sequentially formed by the same die-forming and anvil components.

Claim 23

Dependent Claim 106 words

The method of claim 1 or claim 2, in which the reaction anvil is selected for peripherally continuous land application to the opposite surface of the substrate; in which, within the land, the anvil has a cavity; in which another premeasured quantity of plastic working material is positioned within said cavity poor to commencement of compressional deformation; and in which the compressive energy is sufficient to soften the other premeasured quantity of plastic material, thereby consolidating the other premeasured quantity with the porous impregnation of the substrate and concurrently forming a molded shape in conformance with the cavity and on the oposite surface of the substrate.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1991-04-05	1991-10-05	1992-04-05	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1995-04-05	1995-10-05	1996-04-05	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1999-04-05	1999-10-05	2000-04-05	$7700.00	Window Closed / Lapsed

Method of making a fastener

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