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GARMENT FASTENER ASSEMBLY AND METHOD FOR MAKING THE SAME A garment fastener assembly is comprised of releasably interlocked subassemblies, each subassembly including a fibrous support member and a unitary fastener in engagement both with opposed surfaces of the fibrous support member and with fibers exposed by rupture of the fibrous support member during manufacture of the subassembly.
Attorney, Agent or Firm: What is claimed is: 1. A method for manufacturing a fastener subassembly comprised of a fibrous member and a unitary fastener element extending in part through said member and secured thereto, comprising the steps of folding onto an elongate non-apertured fibrous strip both longitudinal edges thereof to thereby laterally space said edges from one another by a distance less than the lateral width of said strip prior to folding said edges thereof, providing a pair of dies respectively defining first and second mold cavities, inserting such folded strip between said dies, closing said dies on said folded strip, introducing fluid molding material into at least one of said cavities, pressurizing said introduced material to selectively rupture an expanse of said folded strip between said edges to provide a passage extending between said cavities for movement of said introduced material therethrough, solidifying said material in said passage and in said cavities and thereafter separating said dies from said strip. 2. The fastener subassembly provided by practicing the method claimed in claim 1. 3. A fastener assembly comprising first and second fastener subassemblies each provided by practicing the method of claim 1, the fastener element of said first fastener assembly having a male projection, the fastener element of said second fastener assembly having a female receptacle matable with said projection. 4. A method for manufacturing a fastener subassembly comprised of a fibrous member and a unitary fastener element extending in part through said member and secured thereto, comprising the steps of folding onto an elongate non-apertured fibrous strip both longitudinal edges thereof to thereby laterally space said edges from one another by a distance less than the lateral width of said strip prior to folding said edges thereof, providing a pair of dies respectively defining first and second mold cavities, inserting such folded strip between said dies, closing said dies on said folded strip, introducing fluid molding material into said first cavity, pressurizing said introduced material to selectively rupture an expanse of said folded strip between said edges to provide a passage extending between said cavities for movement of said introduced material into said second cavity, solidifying said material in said passage and in said cavities and thereafter separating said dies from said strip. FIELD OF THE INVENTION This invention relates to garment fasteners and more particularly to fastener subassemblies comprising fibrous members having unitary fastener elements extending therethrough and to methods of manufacturing the same. BACKGROUND OF THE INVENTION In garment manufacture, recent style transitions to close-fitting apparel, e.g., so-called body suits for women, have occasioned greater demands for unobtrusive fasteners of increased strength. In the interests of efficiency in manufacture of this type of apparel the industry has generally adopted a fastener having cooperative subassemblies, each including a support member and a male or female fastener element joined thereto. The support members are sewn to garment portions intended to be releasably secured to one another. Cognizant of the principal weakness in fasteners, i.e., the tendency for separation of the fastener element from its support, the art has undertaken various measures intended to extend the area of contact between the fastener element and its support and to improve the bonding force therebetween. These prior art efforts fall generally into one of three classifications. In a first grouping, illustrated in U.S. Pat. Nos. 2,548,004; 3,176,365; 3,195,201; and 3,396,436; such efforts involve the provision of a non-unitary fastener element comprising two preformed interlocking parts disposed on opposite sides of a support member and joined together through the member. In a second grouping, shown in U.S. Pat. Nos. 3,019,152 and 3,169,292, they involve the provision of a preformed unitary plastic fastener element and a non-apertured support member and subsequent joinder of the fastener element to one side of the support member by rendering a surface portion of the fastener element fluid, e.g., by application of heat. In a third grouping, disclosed in U.S. Pat. No. 2,821,764, these efforts involve the provision of an apertured support member and the molding in situ thereon of a unitary fastener element, fluid plastic passing freely through the support member apertures to form portions of the molded fastener element on both sides of the member. Fasteners of the first grouping have evident shortcomings as respects economy in manufacture since the fastener elements thereof are required to be preformed in multiple interfitting parts. In the case of fasteners of the second grouping, they are limited in strength since they do not have any fastener element structure extending completely through the support member. As to the third grouping, fastener manufacture is complicated by the need for providing an apertured strip member and carefully positioning the same relative to the fastener molding dies. SUMMARY OF THE INVENTION It is an object of the present invention to provide improved garment fastener assemblies and subassemblies and simplified methods for manufacturing the same. It is a more particular object of the invention to provide a simplified method for manufacturing fastener subassemblies of the type wherein unitary fastener elements have structure extending completely through support members. In brief summary thereof, methods of the invention comprise, in the case of male fastener element forming, the insertion in a mold, of a first non-apertured fibrous support member and the introduction of fluid molding material into the mold at at least one side of the fibrous member under pressure sufficient to rupture a selective portion of the fibrous member. The fluid plastic forming the fastener element is thus provided with passage through the ruptured portion of the fibrous member and accordingly adheres to interstices of the fibrous member at both sides of the strip member and to fibers exposed at the ruptured portion thereof. In the case of female fastener element forming in accordance with the invention, a second non-apertured fibrous support member is inserted in a mold and fluid molding material is introduced into the mold at at least one side of the fibrous member at a pressure sufficient to force the material through the member interstices, thereby providing for the disposition of the fibrous member interiorly of the molded fastener element throughout the common extents of the member and element. Fastener subassemblies in accordance with the invention are those produced by such methods. Fastener assemblies of the invention comprise matable pairs of subassemblies so produced. Other objects and features of the invention will be evident from the following detailed description of preferred embodiments thereof and from the drawings wherein like reference numerals identify like parts throughout. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 illustrates a fibrous strip member in facing relation to separated dies of a mold configured to form a male fastener element and fastener subassembly in accordance with the invention. FIG. 1A illustrates a preferred fibrous strip member arrangement. FIG. 2 shows the dies of FIG. 1 in operative position for forming a male fastener element on the strip member of FIG. 1. FIG. 3 illustrates the male fastener subassembly formed in the FIG. 2 operation. FIG. 4 illustrates a fibrous strip member in facing relation to separated dies of a mold configured to form a female fastener element and fastener subassembly in accordance with the invention. FIG. 5 illustrates the female fastener subassembly formed in the FIG. 4 operation. DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring to FIG. 1, fibrous strip member 10, comprised of a fibrous material, woven or non-woven, e.g., cotton, and defining continuous and unapertured outer surfaces 10a and 10b, is disposed between a pair of separates dies 12 and 14. Die 12 defines a generally hemispherical mold cavity 16 having an access port 20 for the introduction of molding material into the cavity. Die 14 defines a cavity 18 of configuration conforming with the desired male fastener element projection. As shown in FIG. 2, when dies 12 and 14 are closed upon member 10, cavities 16 and 18 engage, and extend respectively upwardly and downwardly of, surfaces 10a and 10b. With the dies and member so arranged, fluid molding material, e.g., plastics, such as acetal resins sold under the trademarks Celcon and Delrin, is introduced through access port 20 into cavity 16. The material may be provided to access port 20 by a conventional injection molding machine having an externally heated extruder cylinder of the screw-feed type. The introduced fluid plastic is pressurized such that member 10 is ruptured in portion 10c thereof, thereby permitting the fluid plastic to gain ingress into cavity 18. As illustrated schematically in FIG. 2, at ruptured portion 10c, individual fibers of member 10 are exposed and intermingle in random fashion with the fluid plastic disposed both in portion 10c and downwardly thereof occupying cavity 18. Since material 10 is fibrous and hence absorbent to the fluid plastic, additional amounts of fluid plastic saturate the expanses of member 10 adjacent the ruptured portion thereof and within the cavity. With the fluid plastic so distributed in this manner in dies 12 and 14, the plastic solidifies. Upon separation of dies 12 and 14, the fastener subassembly illustrated in FIG. 3 is provided. As will be evident, this subassembly includes a unitary fastener element having male projection 22 conforming in configuration with mold cavity 18, generally hemispherical portion 24 extending upwardly of surface 10a and a further portion 26 intervening portion 24 and projection 22 and integral therewith. As occasioned by the rupturing activity above discussed, the fastener subassembly includes a random distribution of fibers embedded in fastener element portion 26 and projection 22 and integral with member 10. The solidified plastic is selected to have sufficient compressibility to permit the tip 22a of projection 22 adjacent undercut 22b to be readily released from die 14. A particularly preferred arrangement for the fibrous support member of fastener subassemblies according with the invention is shown in FIG. 1A. In this arrangement, marginal portions 11a and 11b of fibrous support member 11 are folded onto the intermediate expanse 11c of the member, with edges 11d and 11e spaced slightly from one another. Member 11 is sewn to the garment such that marginal portions 11a and 11b are adjacent the garment surface and thus unfinished edges are not exposed. As will be appreciated, the spacing of edges 11d and 11e provides for a reduced strength zone in this arrangement whereby occurrence of the above-discussed rupture may be further facilitated above and beyond the facilitation of rupture by the configuration of mold cavity 18. Referring to FIG. 4, fibrous member 28 is disposed between separate dies 30 and 32, die 30 defining a cavity 34 of configuration conforming with the desired female fastener element receptacle and die 32 defining a generally hemispherical mold cavity 36. Die 32 includes an access port 38 for the introduction of molding material into cavity 36. Upon closure of the dies onto member 28 and introduction of fluid plastic into cavity 36, the fluid plastic permeates the interstices of member 28 and flows into cavity 34, thereby providing fastener element portions on both sides of the enclosed fibrous member as shown in FIG. 5 which illustrates the completed fastener element subassembly. While the above-discussed rupture may occur in the FIG. 4 molding operation, the same is not requisite since member 28 defines extensive surface area and volume interiorly of the female fastener element. Various combinations of molding materials and fibrous members are of course usable in practicing the invention and molding pressures, molding temperatures and solidifying temperatures are selected accordingly. The example below describes the particularly preferred practice of the invention. EXAMPLE A strip of cotton of breaking strength of approximately 200 to 300 pounds and of a thickness of 0.007 inch is placed between opposed dies as in FIG. 1 and the dies are closed thereon as in FIG. 2. Delrin molding material, heated to above its melting temperature, i.e., to about 350.degree.F., is fed through one of the dies at a pressure of 15 to 20 thousand psi. The dies are maintained at temperatures between 100.degree.F. and 200.degree.F., e.g., by water cooling. The cotton strip is ruptured and the Delrin material flows throughout the cavities of both dies. The material thereupon solidifies and the dies are separated. Upon inspection of the male fastener element subassembly so formed, fibers of cotton in the strip rupture area are seen to extend from the strip into the molding material forming the male projection. Various changes and modifications, evident to those skilled in the art, may be introduced without departing from the spirit of the invention. For example, the molding material may be introduced in FIG. 1 through a port in die 14 instead of through port 20 of die 12. Where a time lag or a pressure differential exists between two pressure lines, molding material may be introduced therefrom respectively through ports in both opposed dies. In this connection, the foregoing preferred embodiments of the invention are intended in an illustrative and not in a limiting sense. For U.S. patent law, rules, and procedures see MPEP. Disclaimer. Information presented on this page while believed to be reliable, is provided "as is" with no warranties of its accuracy or timeliness. For legal advice seek help of a licensed professional. |