Fastener Systems for Seat Cushions
Touch fasteners are provided, including a sheet-form base, a plurality of male fastener elements extending upwardly from the sheet-form base, and a foam, bonded to the sheet-form base. Seat cushions and methods of forming seat cushions are also provided.
1 . A fastener product comprising:
a fastener tape carrying male fastener elements on a first side,
a foam layer bonded to a second, opposite side of the fastener tape, and
a polymeric film having a surface energy of at least 35 dynes/cm adjacent the foam layer and exposed for contact by a liquid polymer during molding.
2 . The fastener product of claim 1 wherein the polymeric film has a surface energy greater than 45 dynes/cm.
3 . The fastener product of claim 1 wherein the polymeric film is selected from the group consisting of polyurethane films, nylon films and polyester films.
4 . The fastener product of claim 1 wherein the fastener elements are integrally molded with a sheet-form base.
5 . The fastener product of claim 1 further including a fabric reinforcement layer.
6 . The fastener product of claim 5 wherein the fabric reinforcement layer is interposed between the foam layer and the hook tape.
7 . The fastener product of claim 1 wherein the film is wider than the foam layer.
8 . The fastener product of claim 1 wherein the fastener tape comprises a base having a predetermined width between longitudinal edges, the foam layer having a width greater than the predetermined width of the base, such that edges of the foam layer extend beyond the longitudinal edges of the base.
9 . A method of making a foam bun, the method comprising:
providing a fastener product comprising a fastener tape carrying male fastener elements on a first side, a foam layer bonded to a second, opposite side of the fastener tape, and a polymeric film having a surface energy of at least 35 dynes/cm adjacent the foam layer and exposed for contact by a liquid polymer during molding;
engaging the film with an upper trench edge, and compressing the foam between trench walls to sealingly position the fastener tape in a trench in a mold cavity; and
delivering a liquid polymer to the mold cavity.
10 . The method of claim 9 wherein the polymeric film has a surface configured so as not to disrupt flow of liquid polymer over the film during molding.
11 . The method of claim 9 further comprising positioning the fastener tape so that the surface of the polymeric film is even with a top surface of the trench.
12 . The method of claim 9 wherein the polymeric film has a non-porous surface.
13 . The method of claim 9 wherein the trench has, in cross-section, a stepped undercut configuration.
14 . The method of claim 10 wherein the polymeric film has a surface energy greater than 35 dynes/cm.
15 . The method of claim 9 wherein the polymeric film is selected from the group consisting of polyurethane films, nylon films and polyester films.
16 . The method of claim 9 wherein the fastener elements are integrally molded with a sheet-form base.
17 . The method of claim 9 further including a fabric reinforcement layer.
18 . The method of claim 17 wherein the fabric reinforcement layer is interposed between the foam layer and the hook tape.
19 . The method of claim 9 wherein the film is wider than the foam layer.
20 . The method of claim 9 wherein the fastener tape comprises a base having a predetermined width between longitudinal edges, the foam layer having a width greater than the predetermined width of the base, such that edges of the foam layer extend beyond the longitudinal edges of the base.