Articles and methods of their formation

• US 20060101626A1
• Filed: 11/15/2004
• Published: 05/18/2006
• Est. Priority Date: 11/15/2004
• Status: Active Grant

• Current Assignee: Velcro IP Holdings LLC
• Original Assignee: Velcro Industries BV (Chartwell Industries Ltd)
• Inventors: Gallant, Christopher M., Kingsford, Howard A., Carr, Gregory A.
• Granted Patent: US 7,461,437 B2
• Time in Patent Office: Days
• US Class Current: 24/442
• CPC Class Codes: A44B 18/0049 obtained by moulding processes compression moulding or articles of indefinite length characterised by the shape of the surface B29C43/222; screen moulding B29C67/08
• CPC Class Codes: A44B 18/0084 Double-sided
• CPC Class Codes: B29C 2043/461 the rollers having specific surface features
• CPC Class Codes: B29C 2043/465 having one or more cavities, e.g. for forming distinct products
• CPC Class Codes: B29C 43/222 characterised by the shape of the surface
• CPC Class Codes: B29C 43/46 Rollers
• CPC Class Codes: B29L 2031/729 Hook and loop-type fasteners
• CPC Class Codes: Y10T 24/27 including readily dissociable fastener having numerous, protruding, unitary filaments randomly interlocking with, and simultaneously moving towards, mating structure [e.g., hook-loop type fastener]
• CPC Class Codes: Y10T 24/2792 having mounting surface and filaments constructed from common piece of material
• CPC Class Codes: Y10T 428/24017 Hook or barb

Abstract

A fastener product includes a base; and an array of fastener projections extending integrally from a first surface of the base, the projections each including a stem portion of resin molded integrally with the first surface of the base, and a head portion disposed at a distal end of the stem portion and configured to releasably engage a complementary fastener element to form a fastening; wherein the stem portions of the fastener projections and at least a portion of the base are integrally formed of a single resin; and wherein at least a portion of the single resin of the base is in a foamed state.

Claims

1. A fastener product comprising

a base;

and

an array of fastener projections extending integrally from a first surface of the base, the projections each comprising a stem portion of resin molded integrally with the first surface of the base, and a head portion disposed at a distal end of the stem portion and configured to releasably engage a complementary fastener element to form a fastening;

wherein the stem portions of the fastener projections and at least a portion of the base are integrally formed of a single resin; and

wherein at least a portion of the single resin of the base is in a foamed state.

2. The fastener product of claim 1, wherein the foamed state comprises a plastic foam.

3. The fastener product of claim 1, wherein the single resin comprises a foaming agent.

4. The fastener product of claim 3, wherein the foaming agent is present in the stem portions of the fastener projections in an unactivated state.

5. The fastener product of claim 1, wherein the single resin is in an unfoamed state in the stem portions of the fastener elements, and in a foamed state in at least a portion of the base.

6. The fastener product of claim 1, wherein the base further comprises a second resin.

7. The fastener product of claim 1, wherein the fastener projections are arranged in a band, the band of fastener projections having a width less than the width of the foamed state of the base.

8. The fastener product of claim 1, wherein the fastener projections are arranged in a patch of fastener projections.

9. The fastener product of claim 1, wherein the foamed state comprises an open cell foam.

10. The fastener product of claim 9, wherein the open cell foam comprises one of a polyether foam or polyester foam.

11. The fastener product of claim 1, wherein the foamed state comprises a closed cell foam.

12. The fastener product of claim 11, wherein the closed cell foam comprises a polyolefin.

13. The fastener product of claim 12, wherein the polyolefin is selected from a group consisting of polyethylene and polypropylene.

14. The fastener product of claim 1, wherein the fastener projections include heads that extend outwardly from stems in multiple directions.

15. The fastener product of claim 1, wherein the fastener projections include heads that extend outwardly from stems in one or more discrete direction.

16. The fastener product of claim 1, wherein the foamed state has a specific gravity of at most about 1.1.

17. The fastener product of claim 16, wherein the foamed state has a specific gravity of at most about 0.7.

18. The fastener product of claim 1, wherein the fastener projections comprise fibers.

19. The fastener product of claim 18, wherein the fibers are secured to the foamed state by an adhesive.

20. The fastener product of claim 18, wherein the fibers form a nonwoven material.

21. The fastener product of claim 20, wherein the nonwoven material is stretched.

22. The fastener product of claim 18, wherein the fibers form a knit material.

23. The fastener product of claim 1, wherein the fastener projections are in the form of hook fastener elements.

24. The fastener product of claim 23, wherein the fastener projections have heads that extend outwardly from associated stems in multiple directions.

25. The fastener product of claim 23, wherein the fastener projections have heads that extend outwardly from associated stems in one or more discrete directions.

26. The fastener product of claim 1, wherein the fastener projections are integrally and continuously joined over an extended region to the base.

27. The fastener product of claim 26, wherein the fastener projections are joined over the extended region to the base without the use of an adhesive.

28. The fastener product of claim 26, wherein the fastener projections are joined over the extended region to the base with adhesive.

29. The fastener product of claim 1, wherein the fastener projections comprise cross-linked resin.

30. A fastener product comprising;

a sheetform base comprising an array of individual fastener elements each having a stem integrally molded with and extending from an upper surface of the base;

wherein the base comprises a plurality of lanes, wherein a first lane comprises a selected resin in a foamed state and a second lane comprises the selected resin in an unfoamed state.

31. The fastener product of claim 30, wherein the first lane is disposed between two second lanes.

32. The fastener product of claim 30, wherein the second lane comprises a foaming agent.

33. The fastener product of claim 30, wherein the resin in the foamed state comprises a closed cell foam.

34. The fastener product of claim 30, wherein the fastener elements include heads that extend outwardly from stems in multiple directions.

35. A method of forming a fastener product comprising a base and an array of fastener elements extending from the base, the method comprising

molding the base and stem portions of the fastener elements of a single resin;

forming loop-engageable head portions on the stem portions of the fastener elements; and

foaming at least a part of the single resin of the base.

36. The method of claim 35, wherein foaming at least a part of the single resin of the base includes generating gas bubbles in the resin.

37. The method of claim 36, wherein the gas bubbles are generated by activating a foaming agent within the resin.

38. The method of claim 37, wherein the fastener elements are formed of a cross-linkable resin.

39. The method of claim 38, comprising cross-linking the cross-linkable resin of the fastener elements prior to foaming at least a part of the single resin of the base.

40. The method of claim 39, wherein cross-linking the resin of the fastener elements includes irradiating the resin with an electron beam.

41. The method of claim 40, wherein cross-linking the resin of the fastener elements includes irradiating the resin with ultraviolet light.

42. The method of claim 37, wherein the foaming at least a part of the single resin of the base is accomplished by applying thermal energy.

43. The method of claim 37, wherein the resin comprises a polymer.

44. The method of claim 43, wherein the polymer is a polyolefin.

45. The method of claim 44, wherein the polyolefin is selected from a group consisting of polyethylene and polypropylene.

46. The method of claim 35, wherein the base is molded while molding the fastener elements.

47. The method of claim 46, wherein the fastener elements are in the form of engageable hooks.

48. The method of claim 47, wherein the hooks are loop-engageable.

49. The method of claim 35, wherein the loop-engageable head portions are formed subsequent to the formation of the stems.

50. The method of claim 35, further comprising securing a field of fibers to the base.

51. The method of claim 50, wherein the field of fibers are configured to engage hook fastener elements.

52. The method of claim 35, comprising

introducing molten resin to a gap defined adjacent a periphery of a rotating mold roll, such that the single resin forms at least a part of the base at the periphery of the mold roll and fills an array of fixed cavities defined in the rotating mold roll to form the fastener elements;

solidifying the single resin; and

stripping the single resin from the periphery of the mold roll by pulling the solidified fastener elements from their respective cavities.

53. The method of claim 52, wherein the single resin is introduced in the form of multiple, spaced-apart bands.

54. The method of claim 52, wherein the single resin is discontinuously introduced to the gap to form patches of projections extending from an associated base.

55. The method of claim 52, wherein the gap is formed between the mold roll and a counter-rotating pressure roll.

56. The method of claim 52, wherein foaming at least a part of the single resin of the base includes activating a foaming agent within the single resin.

57. The method of claim 56, wherein the foaming agent is activated before the single resin is introduced to the gap.

58. The method of claim 56, wherein the foaming agent is activated while the single resin is introduced to the gap.

59. The method of claim 56, wherein the foaming agent is activated after the single resin is introduced to the gap.

60. The method of claim 59, wherein the foaming agent is activated prior to stripping the single resin from the periphery of the mold roll.

61. The method of claim 59, wherein the foaming agent is activated subsequent to stripping the single resin from the periphery of the mold roll.

62. The method of claim 52, wherein foaming at least a part of the single resin of the base includes charging the single resin with gas before the resin passes through the gap.

63. The method of claim 52, further comprising introducing a second resin to the gap to bond the second resin and the resin forming at least part of the sheet-form base at the periphery of the mold roll, the second resin including a foaming agent.

64. The method of claim 63, further comprising introducing a preformed substrate defining hook-engageable loops to the second resin to bond the substrate to the second resin.

65. The method of claim 64, wherein the substrate is in the form of a discrete band and introduced to the second resin such that the second resin is exposed adjacent the discrete band of substrate.

66. The method of claim 63, wherein foaming at least a part of the single resin of the base comprises activating the foaming agent within the second resin.

67. The method of claim 52, wherein the cavities are stem-shaped to form fastener element stems extending integrally from the base.

68. The method of claim 67, further comprising post forming distal ends of the stems to form heads that overhang the base.

69. The method of claim 52, wherein the cavities include head forming portions to form engageable fastener elements comprising heads that overhang the base and stems extending integrally from the base.

70. The method of claim 35, wherein the plastic foam has a specific gravity of at most about 1.1.

71. The method of claim 70, wherein the foamed part of the single resin of the base has a specific gravity of at most about 0.7.

72. A method for forming a fastener product comprising:

securing a preformed sheet of foam material to a broad surface of a sheet-form base of a fastener component having an array of hook fastener elements including stems that extend outwardly from the base, the base being integrally and continuously joined over an extended region to the preformed sheet of foam material; and

securing a mating fastener component to the preformed sheet of foam material, the mating fastener component having an array of fastener-engageable elements arranged to engage the hook fastener elements.

73. The method of claim 72, wherein the preformed sheet of foam material is secured to the broad surface of the base opposite a surface from which the hook fastener elements extend.

74. The method of claim 72, wherein securing the preformed sheet of foam material to the broad surface of the base comprises flame laminating.

75. The method of claim 72, wherein the foam material is selected from a group consisting of foamed polyester and foamed polyether.

76. The method of claim 72, wherein the base and hook fastener elements are formed of a thermoplastic resin.

77. The method of claim 72, wherein the foam material has a specific gravity of less than about 1.1.

78. The method of claim 77, wherein the foam material has a specific gravity of less than about 0.7.

79. The method of claim 72, wherein the fastener-engageable elements are loops of a loop material.

80. The method of claim 79, wherein the loop material is a nonwoven material.

81. The method of claim 79, wherein the loop material is a woven material.

82. The method of claim 79, wherein the loop material is a stretched nonwoven material.

83. The method of claim 72, wherein the fastener elements have heads extending laterally from stems in multiple directions.

84. The method of claim 72, wherein the fastener elements have heads that extend laterally from stems in one or more discrete directions.

85. The method of claim 72, wherein the fastener-engageable elements are hook fastener elements.

86. A method of forming a sheetform fastener product comprising a sheetform base and an array of individual fastener elements each having a stem integrally molded with and extending from an upper surface of the base, the method comprising:

extruding resin into a nip defined between a pressure surface and a rotating mold roll defining discrete cavities extending inwardly from an outer surface thereof;

molding the sheetform base of the resin while molding at least the stems of the fastener elements in the cavities; and

foaming a portion of the resin of the sheetform base.

87. The method of claim 86, further comprising extruding a second resin into the nip, wherein the second resin is foamed to provide the foam on the lower surface of the base.

88. The method of claim 86, further comprising introducing a material into the nip, wherein the material becomes secured to the foam on the lower surface of the base.

89. The method of claim 86, wherein foaming at least a part of the single resin of the base includes generating gas bubbles in the resin.

90. The method of claim 89, wherein the gas bubbles are generated by activating a foaming agent within the resin.

91. A method of forming a sheetform fastener product comprising a sheetform base and an array of individual fastener elements each having a stem integrally molded with and extending from an upper surface of the base, the method comprising:

extruding from an extruder having a contoured shape a resin as multiple lanes into a nip defined between a pressure surface and a rotating mold roll defining discrete cavities extending inwardly from an outer surface thereof, the multiple lanes including at least one lane of a first resin and another lane of a second resin;

molding the sheetform base of the first and second resin while molding at least the stems of the fastener elements in the cavities of the first resin; and

foaming the second resin.

92. The method of claim 91, wherein the second resin includes a foaming agent.

93. The method of claim 91, wherein the second resin is foamed prior to entering the nip.