Fastener webs with microstructured particles and methods of making same

Abstract

A hook fastener capable of engaging a suitable loop fabric, and a method of forming this hook fastener, are disclosed. The hook fastener comprises a base substrate with a surface having a multitude of engaging projections, the engaging projections having a top surface and an attached end which is joined to the surface of the base substrate at a bond juncture, wherein the top surfaces of at least some of the engaging projections comprise nonlinear microstructured features, such as intersecting peak and/or valley structures.

1 . A hook fastener capable of engaging a suitable loop fabric, comprising;
 a base substrate with a surface having a multitude of engaging projections, the engaging projections having a top surface and an attached end, wherein the attached end is joined to the surface of the base substrate at a bond juncture, and wherein the top surface of at least some of the engaging projections are formed with intersecting peak and/or valley structures.   
   
   
       2 . The hook fastener of  claim 1 , wherein at least some of the peak structures are discrete structures surrounded by valley structures. 
   
   
       3 . The hook fastener of  claim 2 , wherein at least some of the discrete peak structures are bounded on three or more sides by material of the top surface at a different height. 
   
   
       4 . The hook fastener of  claim 1 , wherein at least some of the valley structures are discrete valley structures surrounded by peak structures. 
   
   
       5 . The hook fastener of  claim 1 , wherein at least some of the peak structures intersect at one or more locations. 
   
   
       6 . The hook fastener of  claim 1 , wherein at least some of the valley structures intersect at one or more locations. 
   
   
       7 . The hook fastener of  claim 1 , wherein at least some of the engaging projections' top surfaces are ellipsoidal in shape. 
   
   
       8 . The hook fastener of  claim 1  wherein the top surface structures have a height of at least about 20 microns. 
   
   
       9 . The hook fastener of  claim 1  wherein the top surface structures have a height of at least about 50 microns. 
   
   
       10 . The hook fastener of  claim 1 , wherein at least some of the engaging projections' top surfaces are non-ellipsoidal in shape. 
   
   
       11 . The hook fastener of  claim 1 , wherein at least some of the engaging projections' top surfaces have at least one edge with a mantle surface that defines an angle of at least about 20 degrees. 
   
   
       12 . The hook fastener of  claim 1 , wherein at least some of the engaging projections' top surfaces have at least one edge with a mantle surface that defines an angle of at least about 30 degrees. 
   
   
       13 . A hook fastener capable of engaging a suitable loop fabric comprising,
 a base substrate with a surface having a multitude of engaging projections, the engaging projections having a top surface and an attached end, wherein the attached end is joined to the base substrate at a bond juncture, and wherein the top surface of at least some of the engaging projections comprise nonlinear microstructured features, and wherein the engaging projections with nonlinear microstructured features have an average height-to-diameter aspect ratio of about 0.7 or greater.   
   
   
       14 . The hook fastener of  claim 13 , wherein the engaging projections have an average height-to-diameter aspect ratio of about 1.0 or greater. 
   
   
       15 . The hook fastener of  claim 13 , wherein the nonlinear microstructured features have a height of at least about 20 microns. 
   
   
       16 . The hook fastener of  claim 13 , wherein the nonlinear microstructured features have a height of at least about 50 microns.