Web having discrete stem regions

Abstract

A web of material having a multiplicity of discrete regions or patches spaced apart from each other on at least a first side of the web, and methods of making the web. A plurality of stems extend from each patch. In certain embodiments, at least a portion of the web may be configured to engage the plurality of the stems, and the web may include a breathable (microporous) and/or elastic material. A method of making a web includes providing a web and discrete quantities of a polymeric material. The polymeric material is fused to the web; and a plurality of stems are formed in each of the discrete quantities of the polymeric material to form fastener patches or regions. The discontinuous fastener patches can function as the male component of a hook-and-loop refastenable mechanical fastener.

1 . A web of material having at least two major sides, the web comprising: 
 a plurality of discrete regions on at least a first major side of the web; and    a plurality of stems extending from each discrete region;    wherein the plurality of stems are fused and formed to at least the first major side of the web.    
     
     
         2 . The web according to    claim 1   , wherein the plurality of stems are attached directly to the first major side of the web.  
     
     
         3 . The web according to    claim 1   , wherein the plurality of stems are comprised of a thermoplastic material selected from the group consisting of: polyurethane, polyolefins, polystyrenes, polycarbonates, polyester, polymethacrylate, ethylene vinyl acetate copolymers, ethylene vinyl alcohol copolymers, polyvinylchloride, acrylate modified ethylene vinyl acetate polymers, and ethylene acrylic acid copolymers.  
     
     
         4 . The web according to    claim 1   , wherein the discrete regions cover between 5 and 25 percent of the first major side of the web.  
     
     
         5 . The web according to    claim 1   , wherein at least a portion of the web is configured and arranged to engage the plurality of stems.  
     
     
         6 . The web according to    claim 1   , wherein the web comprises an elastic material.  
     
     
         7 . The web according to    claim 6   , wherein the elastic material is selected from the group consisting of: natural and synthetic rubbers; styrene block copolymers containing isoprene, butadiene, or ethylene(butylene) blocks; metallocene-catalyzed polyolefins, polyurethanes, and polydiorganosiloxanes.  
     
     
         8 . The web according to    claim 1   , wherein the web defines a localized plane, and the plurality of stems are oriented at a plurality of angles to the localized plane.  
     
     
         9 . The web according to    claim 1   , wherein one or more of the stems is shaped to provide directional hooking capability.  
     
     
         10 . The web according to    claim 1   , wherein the discrete regions are separated an average of approximately 0.05 and 30 centimeters from one another.  
     
     
         11 . A method of making a web material having a plurality of stems extending from discrete regions of the web, the method comprising: 
 (a) providing a web;    (b) providing discrete quantities of a polymeric material at a temperature above its softening point;    (c) fusing the discrete quantities of the polymeric material to the web; and    (d) forming a plurality of stems in each of the discrete quantities of the polymeric material.    
     
     
         12 . The method according to    claim 11   , wherein fusing the discrete quantities of polymeric material to the web occurs simultaneously with forming a plurality of stems in each of the discrete quantities of polymeric material.  
     
     
         13 . The method according to    claim 11   , wherein the discrete quantities of polymeric material are provided by extruding molten polymer in a form selected from intermittent quantities and continuous ribbons.  
     
     
         14 . The method according to    claim 11   , wherein the discrete quantities of polymeric material are provided by one or more rotating cutting blades positioned intermediate a source of polymeric material and the web, wherein the cutting blades cut the polymeric material into discrete quantities.  
     
     
         15 . The method according to    claim 11   , further comprising deformation of the stems with a heated surface to produce an enlarged end on the stems.  
     
     
         16 . The method according to    claim 11   , further comprising re-orienting the stems with a heated surface.  
     
     
         17 . A method of making a web material having a plurality of stems extending from at least one side of the web, the method comprising: 
 (a) providing a polymeric web comprising a polymer at a temperature above its softening point;    (b) providing a tool having a surface with a plurality of stem-forming holes configured in discrete regions; and    (c) pressing the web against the tool surface under pressure to form regions of stems on the surface of the web.    
     
     
         18 . The method of    claim 17    in which the discrete regions of stem-forming holes are formed by masking a portion of the stem-forming holes in the tool of part (b).  
     
     
         19 . The method according to    claim 17   , further comprising deformation of the stems with a heated surface to produce a disk-shaped end on the stems.  
     
     
         20 . The method of    claim 17    in which between 5 and 25 percent of the surface area of the tool of part (b) is occupied by the stem-forming holes.