Abstract:
A male touch fastener strip includes an elongated base having a thickness and defining a longitudinal direction and a lateral direction perpendicular to the longitudinal direction across the base between longitudinal edges of the base, and a field of male fastener elements each having a stem extending from a broad face of the base and a head at an upper end of the stem and overhanging the base for engaging fibers. The fastener element stems and broad face of the base together form a unitary mass of resin. The male touch fastener strip also includes longitudinal barrier walls rising from the broad face of the base on either side of the field of male fastener elements, and a pair of segmented walls rising from the broad face of the base, each segmented wall of the pair disposed laterally outboard of a respective nearest one of the longitudinal barrier walls and including a series of wall segments defining longitudinal gaps therebetween. Each segmented wall and its nearest longitudinal barrier wall define therebetween a foam relief space for receiving a foam material. Each segmented wall defines a flow gap for allowing the foam material to enter the foam relief space.

Description:
TECHNICAL FIELD 
       [0001]    The present invention relates to touch fastening products, and more particularly to touch fastening products configured to be incorporated into molded articles. 
       BACKGROUND 
       [0002]    Traditionally, hook-and-loop fasteners comprise two mating components that releasably engage with one another, thus allowing coupling and decoupling of the two surfaces or objects. The male fastener portion typically includes a substrate having fastener elements, such as hooks, extending from the substrate. Such fastener elements are referred to as “loop-engageable” in that they are configured to releasably engage with fibers of the mating component to form the hook-and loop-fastening. 
         [0003]    Among other things, hook-and-loop fasteners are employed to attach upholstery to car seat cushions. Car seat cushions are typically made of a foam material. To attach the upholstery to the foam, one fastener product is incorporated at a surface of the foam car seat and the mating component is incorporated into the upholstery, or is provided by the upholstery itself. The male fastener elements releasably engage with the mating component to couple the upholstery to the foam car seat. 
         [0004]    To incorporate a male fastener product into a foam cushion, the fastener product may be positioned within a cushion mold, such that as foam fills the mold to form the cushion, the foam adheres to the fastener product. Flooding of the fastener elements by the foam during forming of the cushion is generally seen as inhibiting the usefulness of the fastener elements, and so several improvements have been made to attempt to avoid such foam intrusion. 
         [0005]    Further advances in the design of fastener products are sought, for this and for other applications. 
       SUMMARY 
       [0006]    One aspect of the invention features a male touch fastener strip including an elongated base having a thickness and defining a longitudinal direction and a lateral direction perpendicular to the longitudinal direction across the base between longitudinal edges of the base, and a field of male fastener elements each having a stem extending from a broad face of the base and a head at an upper end of the stem and overhanging the base for engaging fibers. The fastener element stems and broad face of the base together form a unitary mass of resin. The male touch fastener strip also includes longitudinal barrier walls rising from the broad face of the base on either side of the field of male fastener elements, and a pair of segmented walls rising from the broad face of the base, each segmented wall of the pair disposed laterally outboard of a respective nearest one of the longitudinal barrier walls and including a series of wall segments defining longitudinal gaps therebetween. Each segmented wall and its nearest longitudinal barrier wall define therebetween a foam relief space for receiving a foam material, each respective foam relief space having a volume per unit strip length. By “volume per unit strip length” we mean the product of the distance between facing surfaces of a respective segmented wall and its nearest barrier wall and the height of the barrier wall. Each segmented wall defines a flow gap for allowing the foam material to enter the foam relief space, each respective flow gap having an area per unit strip length. By “flow gap” we mean the total exposed area of all flow enabled openings through and around a segmented wall. The ratio of foam relief space volume per unit strip length and flow gap area per unit strip length is between about 0.02 and 0.80 inch. 
         [0007]    The ratio of foam relief space volume per unit strip length and flow gap area per unit strip length is preferably between about 0.20 and 0.50 inch, more preferably between about 0.30 and 0.45 inch. In some cases, this ratio is about 0.40 inch. 
         [0008]    In some embodiments, each respective foam relief space has a width along the lateral direction of the base, and the combined widths of the foam relief spaces is between 10 and 35 percent of a width of the elongated base. 
         [0009]    In some examples, the barrier walls each have a height at least as great as that of the male fastener elements. 
         [0010]    In some implementations, the series of wall segments of each of the segmented walls extends from the broad face of the base to a height not greater than that of the nearest longitudinal barrier wall. In some applications, the height of the series of wall segments of each of the segmented walls is at least 0.004 inch less than the height of the nearest longitudinal barrier wall. In some implementations, the wall segments of each of the segmented walls extend from the broad face of the base to a height not greater than that of the male fastener elements. 
         [0011]    In some cases, the elongated base includes a magnetically attractable material. In some examples, the male touch fastener strip further includes a lateral barrier wall spanning a length in the lateral direction of the base defined by facing surfaces of the longitudinal barrier walls. In some implementations, the lateral barrier wall extends from the broad face of the base to a height not greater than that of either of the longitudinal barrier walls. Some examples of the male touch fastener strip feature a plurality of lateral barrier walls, each spanning a length in the lateral direction defined by facing surfaces of the longitudinal barrier walls. In some applications, the lateral barrier walls and the longitudinal barrier walls form fastening cells that circumscribe one or more of the male fastener elements. In some applications, the lateral barrier walls are spaced apart from one another by between 0.3 and 0.5 inch in the longitudinal direction. In some examples, the fastener strip further includes a series of slits formed between adjacent lateral barrier walls, with each slit extending inward in the lateral direction from one longitudinal edge of the base towards an opposing longitudinal edge. In some cases, each slit is paired with a notch formed at the opposing longitudinal edge of the base. In some applications, a first slit is oriented from a first longitudinal edge of the base, and a second slit is oriented from a second longitudinal edge of the base, with the first longitudinal edge opposing the first longitudinal edge. 
         [0012]    In some implementations, the male touch fastener strip further includes a respective plurality of foam disruptors extending from the broad face of the base within each of the foam relief spaces. In some cases, the foam disrupters in each respective foam relief space are spaced apart from one another in the longitudinal direction. The foam disrupters may include a plurality of spikes, for example, configured to disturb the structure of the foam material. In some applications, the foam disrupters include a plurality of stems or prongs configured to disturb the formation of the controlled amount of foam material. In some implementations, the foam disrupters have a height of about 0.01 inch. In some other examples, the foam disrupters have a height between about 1 and 100 nanometers. 
         [0013]    Some examples feature foam disrupters extending from facing surfaces of a respective segmented wall and its nearest longitudinal barrier wall. 
         [0014]    In some examples, the flow gap area per unit strip is between about 8 and 50 percent of an effective area of the segmented wall. 
         [0015]    In some cases, the male touch fastener strip further includes a respective hinge incorporated into the broad face of the base and extending longitudinally within each of the foam relief spaces. In some implementations, the hinges are in the form of continuous indentations integrally molded with the broad face of the base. In some examples, each of the hinges includes a series of perforations through the base. 
         [0016]    In some cases, the longitudinal gaps have a maximum width of at least about 0.02 inch along the longitudinal direction of the base. 
         [0017]    Some examples of the fastener strip have a chain of fastening segments, each segment including respective longitudinal portions of the base, the field of male fastener elements, the longitudinal barrier walls and the segmented walls. Each segment is connected to at least one adjacent segment of the chain by a flexible neck of less width than the segment. In some cases, each of the longitudinal portions of the base includes a magnetically attractable material. In some implementations, each of the fastening segments includes a pair of lateral barrier walls spanning a length in the lateral direction defined by facing surfaces of the longitudinal barrier walls, and wherein the lateral barrier walls and the longitudinal barrier walls of each fastening segment form a fastening cell that circumscribes one or more of the male fastener elements. In some embodiments, each fastening segment includes at least one male fastener that is outside of the fastening cell. In some examples, the male touch fastener strip further includes a plurality of foam disruptors extending from the broad face of the base within each of the foam relief spaces, each of the fastening segments carrying at least one of the foam disrupters. In some examples, the male touch fastener strip further includes a respective hinge incorporated into the broad face of the base and extending longitudinally within each of the foam relief spaces, the portion of the base of each of the fastening segments including a portion of each hinge. 
         [0018]    Another aspect of the invention features a male touch fastener strip with an elongated base having a thickness and defining a longitudinal direction and a lateral direction perpendicular to the longitudinal direction across the base between longitudinal edges of the base, and a field of male fastener elements each having a stem extending from a broad face of the base and a head at an upper end of the stem and overhanging the base for engaging fibers. The fastener element stems and broad face of the base together form a unitary mass of resin. The male touch fastener strip also includes longitudinal barrier walls rising from the broad face of the base on either side of the field of male fastener elements, and a pair of segmented walls rising from the broad face of the base, each segmented wall of the pair disposed laterally outboard of a respective nearest one of the longitudinal barrier walls along a respective longitudinal base edge and including a series of wall segments defining longitudinal gaps therebetween. The male touch fastener strip also includes a series of discrete foam disruptors disposed in a space between one of the segmented walls and its respective longitudinal barrier wall, the foam disrupters each forming a barb spaced from the segmented walls and longitudinal barrier walls and arranged to disrupt formation of bubbles of foam within the space. 
         [0019]    Yet another aspect of the invention features a male touch fastener strip with an elongated base having a thickness and defining a longitudinal direction and a lateral direction perpendicular to the longitudinal direction across the base between longitudinal edges of the base, and a field of male fastener elements each having a stem extending from a broad face of the base and a head at an upper end of the stem and overhanging the base for engaging fibers. The fastener element stems and broad face of the base together forming a unitary mass of resin. The male touch fastener strip also includes longitudinal barrier walls rising from the broad face of the base on either side of the field of male fastener elements, and a pair of segmented walls rising from the broad face of the base, each segmented wall of the pair disposed laterally outboard of a respective nearest one of the longitudinal barrier walls along a respective longitudinal base edge and including a series of wall segments defining longitudinal gaps therebetween. The broad face of the base is structured to define hinges between the segmented walls and their respective longitudinal barrier walls, the hinges including discrete flex points of the base, each dividing the base between a central base section and a respective edge section, and in which the base is substantially more flexible than in its base section and edge sections. 
         [0020]    Yet another aspect of the invention features a male touch fastener strip with an elongated base having a thickness and defining a longitudinal direction and a lateral direction perpendicular to the longitudinal direction across the base between longitudinal edges of the base, and a field of male fastener elements each having a stem extending from a broad face of the base and a head at an upper end of the stem and overhanging the base for engaging fibers. The fastener element stems and broad face of the base together form a unitary mass of resin. The male touch fastener strip also includes: two longitudinal barrier walls rising from the broad face of the base, each longitudinal barrier wall disposed on a respective side of the field of male fastener elements; a plurality of pairs of lateral barrier walls extending across the field between facing surfaces of the longitudinal barrier walls, the pairs of lateral barrier walls separating the field of male fastener elements into discrete field portions; and a series of slits through the elongated base, each slit disposed between the barrier walls of each pair and extending from one longitudinal edge of the base across more than half a width of the base, such that planar flexure of the base at each one of the slits opens an angle between one of the pairs of lateral barrier walls. 
         [0021]    In some examples, each slit is paired with a notch formed at the opposing longitudinal edge of the base. In some applications, longitudinally adjacent slits extend from different longitudinal edges of the base. In some cases, each slit extends across one of the longitudinal barrier walls and terminates between the barrier walls. In some implementations, each lateral barrier wall spans an entire width of the strip between the longitudinal barrier walls 
         [0022]    Yet another aspect of the invention features a male touch fastener strip with an elongated base having a thickness and defining a longitudinal direction and a lateral direction perpendicular to the longitudinal direction across the base between longitudinal edges of the base, and a field of male fastener elements each having a stem extending from a broad face of the base and a head at an upper end of the stem and overhanging the base for engaging fibers. The fastener element stems and broad face of the base together forming a unitary mass of resin. The base comprises a series of longitudinally spaced base segments, each segment carrying a respective portion of the field of male fastener elements, adjacent base segments connected by a respective hinge formed by a single interconnecting base portion disposed closer to one of the longitudinal edges of the base than to another of the longitudinal edges of the base. 
         [0023]    In some examples, each respective hinge features: a slit through the base and extending from one of the longitudinal edges of the base, across more than half of a width of the base between the longitudinal edges to the interconnecting base portion, and a notch through the base, the notch longitudinally aligned with the slit and disposed at an opposite longitudinal edge of the strip. 
         [0024]    In some applications, with the strip arranged in a longitudinally straight condition, the slit is closed and the notch is open. 
         [0025]    Many of the features of the examples described herein can help to promote secure attachment of the fastener strip within a foam body, such as a seat cushion. At least some of these features derive in part from the realization that a particularly controlled flow of foaming resin into the structure of the lateral edges of the fastening strip can be particularly advantageous in that regard, while leaving a sufficient proportion of the fastening elements exposed for engagement. The flow control achievable by the concepts described herein is even more important in fastener strips with relatively narrow fields of fastener elements, to achieve a secure attachment without overly reducing fastening properties. 
         [0026]    The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims. 
     
    
     
       DESCRIPTION OF DRAWINGS 
         [0027]      FIGS. 1A-1C  are perspective, side, and top views of a first fastening product. 
           [0028]      FIGS. 1D and 1E  are perspective and side views of the fastening product of  FIG. 1 , held against the surface of a mold pedestal. 
           [0029]      FIG. 1F  is a side view of a first fastening product modified for ease of manufacturing. 
           [0030]      FIG. 1G  is a perspective view of a first fastening product modified to accommodate lateral bending. 
           [0031]      FIG. 1H  is a top view of a first fastening product modified to accommodate lateral bending about a relatively strong hinge point. 
           [0032]      FIGS. 2A-2C  are perspective, side, and enlarged views of a second fastening product. 
           [0033]      FIGS. 3A-3C  are perspective, front, and enlarged views of a third fastening product. 
           [0034]      FIGS. 4A-4C  are front, side, and enlarged views of a fourth fastening product. 
           [0035]      FIGS. 5A and 5B  are perspective and top views of a fifth fastening product. 
           [0036]      FIGS. 6A-6D  schematically and sequentially illustrate a process for forming a molded foam article with a fastening product embedded in one surface of the article. 
           [0037]      FIG. 7  is a side view of an apparatus for forming a fastening product. 
           [0038]      FIG. 8  is a side view of an apparatus for forming a fastening product as a coextrusion. 
       
    
    
       [0039]    Like reference symbols in the various drawings indicate like elements. 
       DETAILED DESCRIPTION 
       [0040]    Referring to  FIGS. 1A-1C , a fastening product  100  includes a substrate  102 , barrier walls  104 , segmented walls  106 , lateral walls  108 , and fastener elements  110 . Substrate  102  defines a longitudinal (i.e., lengthwise) direction  101 , and a lateral (i.e., widthwise) direction  103  that is perpendicular to the longitudinal direction. The substrate is a flexible, elongated base sheet of molded resin. Barrier walls  104  are continuous and extend integrally from an upper surface  112  of the substrate  102 . In this example, the fastener product includes a pair of barrier walls spanning the length of the substrate in the longitudinal direction. Each of barrier walls  104  are positioned inboard of a respective longitudinal edge  114  of substrate  102 . 
         [0041]    When fastening product  100  is held against a flat surface, such as a surface of a mold pedestal (as discussed in detail below), barrier walls  104  contact the mold pedestal surface to inhibit (if not prevent) flowing resin from contacting fastening elements  110 . Accordingly, in this example, the height of barrier walls  104  is at least as great as that of fastener elements  110 . In some implementations, however, barrier walls  104  can be slightly shorter than fastener elements  110  (e.g., 0.004 inch or less in height). In these implementations, the barrier walls may not contact the mold pedestal surface. In some examples, a gap exists between the barrier walls and the flat surface of the pedestal that is small enough to inhibit or prevent foam intrusion. In some examples, the fastener elements are configured to bend or compress when held by force against the mold pedestal, to bring the barrier walls in contact with the flat surface of the pedestal. 
         [0042]    Each of segmented walls  106  are disposed outboard of a respective barrier wall  104  (in lateral direction  103 ). In this example, segmented walls  106  are positioned along respective longitudinal edges  114  of substrate  102 . Other appropriate configurations, however, can also be implemented. For example, segmented walls  106  can be positioned substantially inboard of longitudinal edges  114 , leaving hangover extensions of the substrate outboard of the segmented walls. In this example, segmented walls  106  extend integrally from upper surface  112  and run parallel to barrier walls  104  down the length of substrate  102 . As shown, each of segmented walls  106  includes a series of discrete wall segments  118 . Wall segments  118  are spaced apart from one another to form longitudinal gaps  120  between adjacent segments. In some examples, the wall segments extend about 0.06 inch in the longitudinal direction of the base. Longitudinal gaps  120  can allow a flowable material (e.g., a liquefied or partially expanded foam) to pass through the segmented wall. In some examples, the longitudinal gaps have a maximum width along the longitudinal direction of the base that is at least about 0.02 inch. In a particular example, the longitudinal gaps have a width of about 0.11 inch. 
         [0043]    Each of segmented walls  106  defines a respective flow gap. A flow gap can be described as the total exposed area of all flow enabled openings through and around the segmented wall. In this example, each of wall segments  118  has a height equaling that of barrier walls  104 . Accordingly, the accumulation of longitudinal gaps  120  defines the flow gap of each segmented wall  106 . In some implementations, however, the wall segments can be shorter than the barrier walls to augment the flow gap (as described in detail below). The dimensions of the flow gaps can be measured in terms of area per unit strip length of substrate  102 . The dimensions of the flow gaps define the amount of foam that is allowed to pass through the segmented walls during the molding process of a foam article. In some examples, the flow gaps constitute between 8 percent and 50 percent of the effective area of the segmented walls. 
         [0044]    Foam passing through segmented walls  106  enters foam relief spaces  122 . The foam relief spaces are delimited by a respective segmented wall and its nearest barrier wall. The dimension of a foam relief space  122  can be measured in terms of its volume per unit strip length of substrate  102 . The volume per unit strip length can be defined as a product of the distance between facing surfaces of a respective segmented wall and its nearest barrier wall and the height of the barrier wall. 
         [0045]    In some cases, imperfections in a mold pedestal surface (e.g., scratches, dents, or uneven surfaces) can allow foam to flow past the barrier walls  104  and into contact with fastener elements  110 . This can be inhibited (if not prevented), however, by permitting foam to enter and set-up in foam relief spaces  122 . In some examples, the cured or solidified foam can form an integral seal with the mold tool surface, preventing flow past the barrier walls. Additionally, allowing the foam to set-up around wall segments  118  can increase the bond strength between fastening product  100  and a foam molded article (e.g., a seat cushion). For instance, the solidified foam around wall segments  118  can act as an anchor holding fastening product  100  to the seat cushion. In some examples, the fastener product is configured to achieve an appropriate ratio of foam relief space volume per unit strip length and flow gap area per unit strip length. This ratio will be referred to herein as the “foam relief ratio”. In some examples, the flow gaps and foam relief space can be appropriately dimensioned to provide an appropriate foam relief ratio. 
         [0046]    Providing a fastener product with an appropriate foam relief ratio allows the foam passing through the flow gaps of segmented walls  106  to expand and set-up around wall segments  118 , without exerting excessive force on fastening product  100 . For example, when the foam relief ratio is too large, a deficient amount of foam enters the foam relief space. As a result, the solidified foam may not provide a strong anchor to the foam molded article. Conversely, when the foam relief ratio is too small, an excessive amount of foam enters the foam relief space. When the excessive amount of foam expands, a force is exerted on the fastening product (e.g., against substrate  102  and barrier walls  104 ). In some cases, the force may be sufficient to urge the fastening product away from the mold pedestal surface, allowing foam to pass under the barrier walls. In some examples, an appropriate foam relief ratio is between about 0.02 and 0.80 inch. Foam relief ratios between about 0.20 and 0.50 inch or about 0.30 and 0.45 inch can also be implemented. 
         [0047]    Fastener elements  110  are flexible and extend upward from upper surface  112  of substrate  102 . The fastener elements are arranged in discrete fields or arrays separated by lateral walls  108 . Each of fastener elements  110  has a head spaced above upper surface  112 , and each head has two distal tips that extend in opposite directions to form loop overhangs (i.e., palm-tree type fastening elements). Thus, the fastener elements are configured to releasably engage fibers of a mating component (not shown) to form a hook-and-loop fastening. Other appropriate types of fastening elements can also be used. For example, J-hook and/or mushroom-type fastening elements can be implemented. 
         [0048]    In this example, lateral walls  108  laterally traverse an inner area between facing surfaces of respective barrier walls  104  to isolate arrays of fastener elements  110 . In some implementations, however, the lateral walls extend beyond the barrier walls, traversing the inner area between facing surfaces of the outer segmented walls. Lateral walls  108 , in conjunction with barrier walls  104  demarcate individual fastening cells  124 . The fastener cells are effectively sealed against ingress of foam, when the fastening product is held against a flat surface of a mold pedestal. As shown, the lateral walls are disposed at predetermined intervals down the length of the substrate. In this manner, lateral walls  108  allow fastener product  100  to be manufactured in continuous spools that can be severed to form various lengths of fastening strips. In some examples, the inner surfaces of the lateral walls are spaced apart from one another by between about 0.3 and 0.5 inch. In some examples, a continuous spool of the fastener product can be severed so as to leave a number of fastening elements  110   a  exposed to foam (as shown in  FIG. 1A ). The exposed fastening elements can act as anchor points to the molded foam article. Further, as with barrier walls  104  and segmented walls  106 , lateral walls  108  can extend integrally from upper surface  112 . The height of lateral walls  108  can be equal to that of barrier walls  104 . 
         [0049]    In a particular example, each of barrier walls  104 , segmented walls  106 , and lateral walls  108  extend from upper surface  112  of substrate  102  to a height of 0.051 inch. Barrier walls  104  and segmented walls  106  are provided having a thickness of 0.012 inch. In a particular example, the distance between facing surfaces of barrier walls  104  is 0.364 inch, and the distance between lateral walls  108  is 0.450 inch. Accordingly, the area of fastening cells  124  is about 0.164 inch. Such fastening cells can, for example, accommodate an array of 18 fastener elements. In a particular example, wall segments  118  have a length of about 0.124 inch and are spaced apart by about 0.029 inch to form longitudinal gaps  120 . In a particular example, the width of foam relief spaces  122  (i.e., the distance between facing surfaces of a segmented wall and its nearest barrier wall) is 0.030 inch. Accordingly, the foam relief ratio is about 0.16 inch. In some examples, the combined width of the foam relief spaces can be between about 10 percent and 35 percent of the total width of the substrate. 
         [0050]    Turning to  FIGS. 1D and 1E , fastener product  100  can be held against a mold pedestal  10 . For example, one or more elements of fastener product  100  can be formed as a contiguous mass of magnetically attractable resin, such that the fastening product is attracted by a magnet to hold it against a flat mold pedestal surface  12 . When fastener product  100  is held against mold pedestal  10 , its barrier walls and lateral walls contact mold pedestal surface  12  such that flow of foam passed the barrier walls and into contact with the fastener elements is inhibited (if not prevented). As discussed above, longitudinal gaps between neighboring outer wall segments of the fastener product provide a flow gap allowing foam to enter appropriately dimensioned foam relief spaces. 
         [0051]      FIG. 1F  shows a modified fastener product  100 ′, where the longitudinal gaps  120 ′ between the wall segments  118 ′ extend partway down the segmented wall  106 ′ (as opposed to entirely down the segmented wall as shown in  FIGS. 1A and 1B ). This modified fastener product can be easier to manufacture while still providing a sufficient flow gap. In this example, the fastener product was designed such that the flow gaps constitute about 8.4 percent of the effective area of the segmented walls. In addition, the foam relief ratio is about 0.40. 
         [0052]      FIG. 1G  shows yet another modified fastener product  100 ″ designed to provide lateral flexibility. Fastener product  100 ″ features a series of slits  119  formed between adjacent lateral walls  108 ″ of each fastening cell  124 ″. Slits  119  extend inward from one longitudinal edge of the base towards the opposing edge. In this example, slits  119  pass entirely through the barrier wall  104  near the opposing longitudinal edge of the base such that each fastening cell  124 ″ is separated from any adjacent cell. As shown, each of slits  119  is paired with a small notch  121  at the opposing longitudinal edge. In this particular example, the notches are formed as a semi-circular indentation formed in the base material. However, it is appreciated the notches might also have other designs without departing from the scope of this disclosure. Together, notch  121  and slit  119  form a hinge point in the base material to accommodate lateral bending. The slit and notch pairs can be oriented on either longitudinal edge of the fastener product. In some examples, the series of slit and notch pairs are formed in a specific pattern (e.g., X number of pairs that allow bending from the left followed by X number of pairs that allow bending from the right. and so on). In some examples, all of the slit and notch pairs are oriented on the same longitudinal edge. Of course, the fastener product can be customized in this regard based on the desired application. 
         [0053]      FIG. 1H  shows still another modified fastener product  100 ′″ designed to provide lateral flexibility. Fastener product  100 ′″ is similar to the previous example. However, in this case, slits  119  terminate at the barrier wall  104  near the opposing longitudinal edge of the base. Thus, in this example, adjacent fastening cells  124 ′″ remain connected to one another by the barrier wall  104 . This design can provide a stronger hinge point, including both the base material and that of the walls rising upward from the broad surface of the base. 
         [0054]    Referring to  FIGS. 2A-2C , another example fastener product  200  includes foam disrupters  226 . Fastener product  200  is similar in its configuration to fastener product  100 . For example, fastener product  200  includes a substrate  202 , barrier walls  204 , segmented walls  206 , lateral walls  208 , and fastener elements  210 . Foam disrupters  226  are located within foam relief spaces  222 . In this example, the foam disrupters  226  extend from the upper surface of substrate  202 . In some other examples, however, foam disrupters can additionally, or alternatively, extend from facing surfaces of a segmented wall and/or its nearest longitudinal wall. 
         [0055]    As shown, foam disrupters  226  are arranged in a straight-line longitudinal sequence, such that each of the foam disrupters is spaced apart from any neighboring foam disrupters by a constant interval. Further, in this example, foam disrupters  226  are aligned with each of longitudinal gaps  220 . As such, the foam disrupters can contact incoming foam before the foam sets-up (e.g., while the foam is still at least partially liquefied) and cannot be effectively disrupted. Other configurations of the foam disrupters can also be used, however. For example, additional foam disrupters that are not aligned with the longitudinal gaps can be provided. Further, in some implementations, the density of foam disrupters per unit strip length of the substrate varies. For instance, a first length of the substrate can be provided with more or less foam disrupters than a second length. In this example, the foam disrupters are provided in the form of small molded spikes or barbs having the shape of a triangular prism. However, other types of foam disrupters can also be used (e.g., upstanding stems or prongs). The height of the foam disrupters is at most equal to that of the fastening elements. 
         [0056]    Foam disrupters  226  are configured to disturb the structure of foam entering the foam relief spaces. For example, the foam disrupters can collapse the foam by breaking foam bubbles. Collapsing foam entering foam relief spaces  222  increases the foam&#39;s density. As a result, the strength the foam is increased while its expansion ratio is decreased. Accordingly, providing an appropriate configuration of foam disrupters  226  allows the foam passing through the flow gaps of segmented walls  206  to expand and set-up in foam relief spaces  222 , without exerting excessive force on fastening product  200 . As noted above, in some cases, expansion of the foam can exert sufficient force to urge the fastening product away from the flat surface of a mold pedestal surface, allowing foam to enter into the interior of the fastening cells. Foam disrupters  226  can also serve as additional anchor points holding the fastener product to a molded article when the foam cures or sets up in the foam relief spaces. 
         [0057]    In a particular example, each of the foam disrupters extends from the upper surface of the substrate to a height of 0.012 inch, and widthwise (i.e., in the lateral direction of the substrate) to 0.006 inch. The foam disrupters are disposed within the foam relief spaces at a constant longitudinal distance interval of about 0.154 inch. 
         [0058]    Other implementations of the foam disrupters can also be used. For example, the foam disrupters can be provided in the form of a surface roughness (e.g., foam disrupters with a height between about 1 and 100 nanometers) applied to one or more of the walls delimiting the foam relief spaces. In some examples, the foam disrupters are placed at random within the foam relief spaces, such that no discernable pattern or sequence is achieved. In some examples, the foam disrupters can have various appropriate sizes and shapes. 
         [0059]    Referring to  FIGS. 3A-3C , another example fastener product  300  includes hinges  328 . Fastener product  300  is similar in its configuration to fastener product  100 . For example, fastener product  300  includes a substrate  302 , barrier walls  304 , segmented walls  306 , lateral walls  308 , and fastener elements  310 . Hinges  328  are incorporated into the upper surface of substrate  302  within foam relief spaces  322 . In this example, hinges  328  are provided in the form of continuous indentations integrally molded with the substrate  302  and positioned just outboard of barrier walls  304 . In some examples, the hinges are at most about 0.008 inch deep. Other implementations of the hinges can also be used (e.g., perforations or folds in the substrate). 
         [0060]    Hinges  328  can allow outer portions  330  (e.g., the portions of the fastener product outboard of the hinges) of the fastener product to flex relative to an inner portion  332 . The degree of flexure is determined based on the material properties of the base substrate and the dimensions of the hinges. In a particular example, the hinges are 0.013 inch wide, and about 0.0065 inch deep. Allowing the outer edge portions to flex relative to the inner portion of the fastener can reduce stress near the longitudinal edges of the substrate. These stresses can result from various operations in forming the molded foam article. For example, in molding the article, stress is imparted on the fastening product near its longitudinal edges when foam expands in the foam relief spaces. High stress also occurs during other common processes such as de-molding and roller crushing. When the fastener product is secured to the molded product, the hinges allow the outer portions to move with the cured foam. As a result, crack formation and propagation near the longitudinal edges is inhibited. 
         [0061]    As shown, hinges  328  extend longitudinally along the length of the substrate, substantially parallel to the barrier walls and segmented walls of the fastening product. However, in some examples, the fastening product can include lateral hinges that traverse the width of the fastener product. The lateral hinges can be incorporated into the backside surface of the substrate  302 , and disposed at predetermined intervals down the substrate&#39;s length. Incorporating lateral hinges into the fastening product can increase flexibility in the longitudinal direction, such that the fastening product is more suited for winding about a take-up roll and forming a continuous spool. 
         [0062]    Referring to  FIGS. 4A-4C , another example fastener product  400  has an augmented flow gap. Fastener product  400  is similar in its configuration to fastener product  100 . For example, fastener product  400  includes a substrate  402 , barrier walls  404 , segmented walls  406 , lateral walls  408 , and fastener elements  410 . In this example, wall segments  418  extend from the upper surface of substrate  402  to a height that is significantly lesser than that of barrier walls  404 . For example, the height of the wall segments is substantially less than the height of the barrier walls (e.g., at least 0.004 inch shorter). In a particular example, the difference in height between the wall segments and the barrier walls is about 0.011 inch. As shown, the height difference provides additional flow openings  444  for foam to enter the foam relief spaces. Accordingly, the flow gap of each segmented wall  406  includes the open area provided by both flow openings  444  and longitudinal gaps  420 . Although, in the illustrated examples, each of the wall segments are the same height, other implementations exist where each of the wall segments has a respective height (for example, some wall segments will be taller or shorter than other wall segments). 
         [0063]    Referring to  FIGS. 5A-5C , another example fastener product  500  includes a chain of multiple fastening segments  501 . Each of the fastening segments includes a substrate  502 , barrier walls  504 , segmented walls  506 , lateral walls  508 , and fastener elements  510  and  510   a . Fastener segments  501  are connected to one another by a flexible neck  546 . More particularly, in this example, the flexible neck connects the base substrates of neighboring fastener segments to one another. As shown, the width of the flexible neck is less than the width of each segment. In some examples, the flexible neck can be flexible around three orthogonal axes. Accordingly, the flexible neck  546  can allow connected fastening units to move relative to one another. 
         [0064]    As shown, the barrier walls  504  and lateral walls  508  of each segment  501  define a fastener cell  524  which seals fastener elements  510  from contact with foam material during a molding process. Fastener elements  510   a , which are disposed outside of fastener cells  524 , remain exposed during the molding process. As such, when fastener product  500  is held against a mold pedestal, flowing foam is allowed to contact and surround fastener elements  510   a , but not fastener members  510 . Therefore, fastener elements  510   a  can act as anchor points for securing fastener product  500  to a molded foam article, while fastener elements  510  remain available for engagement to a mating fastening component. 
         [0065]    In some examples, the barrier walls and segmented walls of each fastening segment provide foam relief spaces that are appropriately dimensioned based on a foam relief ratio (as described above). In some examples, each of the fastening segments includes multiple foam disrupters positioned within the foam relief spaces (as described above). The foam disrupters can be configured to disturb the structure of foam entering the foam relief spaces. In some examples, each of the fastening segments includes hinges positioned in the foam relief spaces (as described above) that allow outer portions of the fastener product to flex relative to an inner portion. 
         [0066]    The fastening products described above may be used in a variety of fastening applications. For example, in addition to conventional foam molding applications, the arrangements of the fastening elements and walls can also be employed on a rigid fastening surface, such as injection molded fastening products. The following description provides details of an example application of a fastening product having the types of configurations discussed above. 
         [0067]    As shown in  FIG. 6A , fastener product  600  is placed on a flat surface  62  of a mold pedestal  60 . Mold pedestal  60  is disposed in the interior space of a mold cavity  64 . Fastener elements  610  of the product face the mold pedestal surface. As described above, the fastener elements are arranged on the surface of the supporting substrate in arrays bounded by the walls of neighboring fastener cells (i.e., the barrier walls  604  and lateral walls  608 ). As shown in  FIG. 6B , fastener product  600  is held against flat surface  62  by an embedded magnet  66  that attracts the fastener product. Magnetic attraction may be due to magnetically attractable resin forming all or part of the fastener product, or may be due to some other magnetically attractable material (e.g., a metal shim or mesh that is secured to or embedded in the substrate of the product). 
         [0068]    Referring to  FIG. 6B , liquid foam resin  68  is introduced into the mold cavity  64 . Liquid foam  68  may constitute a single component, or there may be multiple components that are mixed as they are introduced into the mold cavity, or before. In some implementations, polymeric foams (e.g., polyurethane foam, latex foam, and the like) are used. As shown in  FIG. 6C , the liquid foam expands to fill the mold cavity. In some examples, the mold cavity can include a number of vents (now shown) to allow gas displaced by the expanding foam to exit the mold cavity. Suitable venting arrangements for the mold cavity are disclosed in U.S. Pat. Nos. 5,587,183 and 7,878,785, the entire contents of which are hereby incorporated by reference. 
         [0069]    As the liquid foam fills the mold cavity, the foam is allowed to pass through segmented walls in the fastening product and enter appropriately dimensioned foam relief spaces. The foam relief spaces allow the foam to expand without forcing the fastener product away from the mold pedestal surface. The walls of the fastening cells effectively seal the interior space housing the fastening elements against the flat pedestal surface. Accordingly, the flowing foam is inhibited from contacting the fastener elements. 
         [0070]    Referring to  FIG. 6D , a molded foam article  69 , as removed from the mold cavity, has fastening product  600  embedded in a trench defined by the mold pedestal. The perimeter of the fastener product is surrounded by foam. Foam also occupies the foam relief spaces, anchoring fastening product  600  to the foam article  69 . The barrier walls and lateral walls of the fastening product form flow barriers to inhibit, if not prevent, foam from contacting the interior fastening elements. As a result, the fastener elements remain exposed and functional to releasably engage with fibers of a mating component (not shown) to form a hook-and-loop fastening. 
         [0071]    Other appropriate molding techniques and apparatus can be used to form a molded article with an incorporated fastener product. For instance, in some examples, the fastening product can be placed directly on a surface of the mold (e.g., in a trench of the mold), as opposed to the mold pedestal surface shown and described herein. 
         [0072]    The fastener products disclosed herein can be formed as flexible, continuous strips or sheets of material in a continuous roll molding process. Referring to  FIG. 7 , manufacturing apparatus  1700  has an extruder barrel  1702  that melts and forces a molten resin  1704  through a die  1706  and into a nip  1708  between a pressure roller  1710  and a cavity roller  1712 . Cavity roller  1712  has cavities  1714  defined about its perimeter  1716  that are shaped to form the fastener elements of the product, and other cavities  1718  that are configured to form the walls of the product, as the base substrate is formed on the outer surface of the cavity roller. Pressure in the nip forces the molten resin into the various cavities, leaving some resin remaining on the cavity roller surface. The resin travels around the cavity roller, which is chilled to promote resin solidification, and the solidified product is then stripped from the cavity roller by pulling the solidified fastener elements and walls from their respective cavities. The fastener elements, walls and their respective cavities are illustrated schematically and are not to scale. In many cases the cavity roller will be of a diameter of between 30 and 50 centimeters, and the fastener elements and walls will be less than 1.5 millimeter in height (as described above), to give a sense of perspective. 
         [0073]    After the continuous length of fastening material is formed, it moves through a die-cutting station  1720 , where discrete fastener products are sequentially severed from the material. The remaining fastener material may be discarded or, in some cases, ground up and recycled to make further material. 
         [0074]    Referring to  FIG. 8 , the apparatus and process of  FIG. 7  may be modified to mold the fastening product from multiple resins, by extruding two molten resins together into the nip. In this example, a sufficient amount of a molten resin  1804   a  is extruded into nip  1808  to form the walls and fastener elements of the fastener product, while another flow of molten resin  1804   b  is introduced to the nip to form the base substrate of the product. The two resins are forced through a cross-head die head  1806  with two different die orifices  1822  and  1824 , to join in the nip. A respective pool of each of the resins forms just upstream of the nip. In the nip, resin  1804   a  is forced into the cavity roller to form the fastener elements and the walls, while resin  1804   b  is calendered to form the substrate. The pressure in the nip also permanently laminates resin  1804   a  with resin  1804   b  to form the finished fastener product. In one example, resin  1804   b  is a magnetically attractable resin, while resin  1804   a  is a resin selected for wall and/or fastener element performance. In another example, the amount of each resin flow is modified such that the amount of resin  1804   a  is sufficient only to fill the head portions of the fastener element cavities and the inner extents of the wall-forming cavities, and is selected to have a lower durometer to provide the finished product with a softer feel and to enhance sealing of the upper wall surfaces against a foaming mold surface. In another example, the amount of each resin flow is adjusted such that resin  1804   a  fills the cavities and forms the upper surface of the substrate, with resin  1804   b  forming only the back portion of the substrate. 
         [0075]    It will be seen by those skilled in the art that many embodiments taking a variety of specific forms and reflecting changes, substitutions, and alternations can be made without departing from the spirit and scope of the invention. Therefore, the described embodiments illustrate but do not restrict the scope of the claims.