Articles and methods of their formation
View Patent ↗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.
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.