Articles and methods of their formation

• US 7,461,437 B2
• Filed: 11/15/2004
• Issued: 12/09/2008
• 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.
• Primary Examiner(s): Miller; William L.
• Application Number:
  US10/989,336
• Publication Number:
  US 20060101626A1
• Time in Patent Office: 1,485 Days
• Field of Search: 244/42, 242/54, 242/52, 244/49, 244/44, 244/52
• 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 seamless body of resin forming both a base and an array of fastener stems extending integrally from a first surface of the base;

head portions disposed at distal ends of the stems and configured to releasably engage a complementary fastener element to form a fastening;

wherein at least a portion of the seamless body of resin is in a foamed state; and

wherein a foaming agent is present in the stems in an unactivated 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 head portions define hooks extending in a longitudinal direction and the stems having molded side surfaces substantially parallel to the longitudinal direction.

4. The fastener product of claim 3, wherein the base comprises a plurality of lanes, wherein a first lane comprises a first portion of the body of resin in the foamed state and a second lane comprises a second portion of the body of resin in an unfoamed state.

5. The fastener product of claim 1, wherein the body of resin is in an unfoamed state in the stems, 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 body of resin.

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

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

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 heads extend outwardly from the associated stems in multiple directions.

15. The fastener product of claim 1, wherein the heads extend outwardly from the associated 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 stems 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 stems and the heads together form hook fastener elements.

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

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

26. The fastener product of claim 1, wherein the stems comprise cross-linked resin.

27. A fastener product comprising:

a seamless body of resin forming both 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;

wherein the base comprises a plurality of lanes, wherein a first lane comprises a first portion of the body of resin in a foamed state and a second lane comprises a second portion of the body of resin in an unfoamed state; and

wherein a foaming agent is present in the stems in an unactivated state.

28. The fastener product of claim 27, wherein the first lane is disposed between two second lanes.

29. The fastener product of claim 27, wherein the second lane comprises a foaming agent.

30. The fastener product of claim 27, wherein the portion of the body of resin in the foamed state comprises a closed cell foam.

31. The fastener product of claim 27, wherein the fastener elements include heads that extend outwardly from stems in multiple directions.