Patent Description:
Certain fasteners have been reported that include different structures on the same fastening member. See, for example, <CIT>); <CIT>); <CIT>); and <CIT>). The different structures may have different shapes, sizes, or abilities to engage.

Some mechanical fasteners with conductive elements have been reported. See, for example, <CIT>), or <CIT>). However, none of the existing solutions have called for a self-mating fastener. Further, these designs are not conducive to being slidable while maintaining an electrical connection. <CIT> discloses a releasable fastener system comprising two hook portions. A first support comprises a plurality of closely spaced upstanding first hook elements on one side thereon. The first hook elements comprise a conductive element and a SMP element.

The present disclosure relates to a self-mating fastener that includes a backing having a first side, and a rail element protruding perpendicularly from the first side of the backing. The rail element extends in a longitudinal direction along the backing. The rail element has a base portion attached to the first side of the backing and a cap portion distal from the backing. The cap portion has a cap width that is greater than a width of the base portion and the cap portion overhangs the base portion on opposing sides. The self-mating fastener includes an electrically conductive contact element proximate to the rail element, and includes all the other features as defined in claim <NUM>.

When used as a system, at least two self-mating fasteners can be slidable relative to each other while maintaining an electrical connection. Additionally, electronic devices can be electrically coupled to the self-mating fastener to facilitate communication from a first electronic device to a second electronic device.

Aspects of the present disclosure relate to a self-mating fastener having electrically conductive contact elements. Additional aspects of the present disclosure also relate to a system of self-mating fasteners arranged such that a first self-mating fastener is slidable with respect to a second self-mating fastener while maintaining an electrical connection.

An embodiment of a fastener of the present invention is shown in <FIG>, and <FIG>. Fastener <NUM> includes a backing <NUM> having a length (l), a width (w), and a thickness (t). Fastener <NUM> includes rows <NUM> of rail segments <NUM>. In the embodiment illustrated in <FIG>, and <FIG>, the rail segments <NUM> protrude perpendicularly from the backing <NUM>. Each of the rail segments <NUM> has a base portion <NUM> attached to the backing <NUM> and a cap portion <NUM> distal from the backing <NUM>. The cap portion <NUM> has a cap width X4 that is greater than the width X1 of the base portion <NUM>, and the cap portion <NUM> overhangs the base portion <NUM> on opposing sides. The ratio of the cap width X4 to the width X1 of the base portion <NUM> is typically at least <NUM>: <NUM>, <NUM>:<NUM>, or <NUM>:<NUM> and can be up to <NUM>:<NUM>, <NUM>:<NUM>, or <NUM>:<NUM>. <FIG> illustrates the cap overhang distance X6. In some embodiments, the cap portion <NUM> overhangs the base portion <NUM> on all sides of base portion <NUM>. <FIG> illustrates the cap overhang distance Y5, in the direction parallel to the length (l) of the fastener <NUM>. Caps also have a cap thickness, which, if the cap is not rectilinear, is measured as a distance between a line tangent to the highest point on the cap above the backing and a line tangent to lowest point on the cap above the backing. For example, in the embodiment shown in <FIG>, the cap thickness is Z1 minus Z2. From the term "rows of rail segments", it should be understood that each row <NUM> includes more than one rail segment <NUM>. The fastener <NUM> does not include a continuous rail; instead the rail segments <NUM> are separated from each other on the backing <NUM>. For example, the caps <NUM> of the rail segments <NUM> in a row <NUM> are separated by cap-to-cap distance Y3 in the direction parallel to the length (l) of the fastener <NUM>.

The base portion <NUM> of the rail segment <NUM> has a length Y1 that is greater than the width X1 of the base portion <NUM>. In some embodiments, the ratio of the length Y1 to the width X1 of the base portion <NUM> is at least about <NUM>:<NUM>, <NUM>:<NUM>, <NUM>:<NUM>, <NUM>:<NUM>, or <NUM>:<NUM>, <NUM>:<NUM>, or <NUM>:<NUM>. The base portion <NUM> of the rail segment <NUM> may have a variety of cross-section shapes. For example, the cross-sectional shape of the base portion <NUM> may be a polygon (e.g., rectangle, hexagon, or octagon), or the cross-sectional shape of the base portion <NUM> may be curved (e.g., elliptical). The base portion <NUM> may taper from its base to its distal end. In this case and in the case of curved base portions, the ratio of the length Y1 to the width X1 of the base portion <NUM> is measured from the longest and the widest point. As shown in <FIG> the length Y1 of the base portion at its longest point is about the same as the length of the cap portion.

For embodiments such as the embodiment illustrated in <FIG>, base portions <NUM> that taper from their bases to their distal ends have a sloping face and a taper angle A1 between the sloping face and the backing <NUM>. In some embodiments, the taper angle A1 between the sloping face of the base portion <NUM> and the backing <NUM> is in a range from <NUM> degrees to <NUM> degrees, in some embodiments, in a range from <NUM> degrees to <NUM> degrees, <NUM> degrees to <NUM> degrees, <NUM> degrees to <NUM> degrees, <NUM> degrees to <NUM> degrees, <NUM> degrees to <NUM> degrees, or <NUM> degrees to <NUM> degrees.

In some embodiments, the rail segments <NUM> have a maximum height Z1 (above the backing <NUM>) of up to <NUM> millimeter (mm), <NUM>, or <NUM> and, in some embodiments, a minimum height of at least <NUM> or <NUM>. The height Z1 of the rail segments <NUM> can be in a range from <NUM> to <NUM>, <NUM> to <NUM>, or <NUM> to <NUM>. The thickness of the cap portion <NUM> (e.g., Z1-Z2) of rail segments <NUM> can be in a range from <NUM> to <NUM>, <NUM> to <NUM>, or <NUM> to <NUM>. In some embodiments, the base portions <NUM> of the rail segments <NUM> have a maximum width X1 of up to about <NUM>, <NUM>, <NUM>, or <NUM> and a minimum width of at least <NUM>, <NUM>, or <NUM>. Some useful widths X1 of the base portions <NUM> are in a range from <NUM> to <NUM>, <NUM> to <NUM>, or <NUM> to <NUM>. Some useful cap widths X4 of the rail segments <NUM> are in a range from <NUM> to <NUM>, <NUM> to <NUM>, <NUM> to <NUM>, or <NUM> to <NUM>. Some useful cap overhang distances X6 of the rail segments <NUM> are in a range from <NUM> to <NUM>, <NUM> to <NUM>, or <NUM> to <NUM>. In some embodiments, the rail segments <NUM> have a maximum length Y1 of up to about <NUM> (in some embodiments, up to <NUM>, <NUM>, <NUM>, or <NUM>) mm and a minimum length Y1 of at least about <NUM>, <NUM>, <NUM>, or <NUM>. The length Y1 of the rail segments can be in a range from <NUM> to <NUM>, <NUM> to <NUM>, or <NUM> to <NUM>. Some useful cap overhang distances Y5 of the rail segments <NUM> in the length direction are in a range from <NUM> to <NUM>, <NUM> to <NUM>, or <NUM> to <NUM>. In some embodiments, the cap-to-cap distance Y3 in the direction parallel to the length (l) of the fastener <NUM> is up to about <NUM>, <NUM>, <NUM>, or <NUM> and at least about <NUM>, <NUM>, or <NUM>. Some useful cap-to-cap distances Y3 are in a range from <NUM> to <NUM>, <NUM> to <NUM>, or <NUM> to <NUM>.

The fastener of the present invention also comprises rows of posts. In the embodiment illustrated in <FIG>, and <FIG>, the fastener <NUM> includes rows <NUM> of posts <NUM> protruding perpendicularly from the backing <NUM>. According to the invention, the rows <NUM> of rail segments <NUM> and rows <NUM> of posts <NUM> alternate. The fastener <NUM> can have at leasts <NUM>, <NUM>, or <NUM> of the rows <NUM> of rail segments <NUM> alternating with at least <NUM>, <NUM>, or <NUM> of the rows <NUM> of posts <NUM> From the term "rows of posts", it should be understood that each row <NUM> includes more than one post <NUM>. The fastener <NUM> does not include a continuous ridge; instead the posts <NUM> are separated from each other on the backing <NUM>. For example, the posts <NUM> in a row <NUM> are separated by a distance Y4 in the direction parallel to the length (l) of the fastener <NUM>. In general, the posts have a length that is different from the length of the rail segments. In the embodiment illustrated in <FIG>, and <FIG>, the length Y1 of the base portion <NUM> of the rail segments <NUM> is greater than the length Y2 of the post <NUM>, and the number of posts <NUM> in one of the rows <NUM> of posts is more than the number of rail segments <NUM> in one of the rows of rail segments <NUM>. The length Y1 of the base portion <NUM> of the rail segments <NUM> can be at least two, three, or four times the length Y2 of the posts <NUM>. The number of posts <NUM> in one of the rows <NUM> of posts can be at least <NUM>, <NUM>, or <NUM> times the number of rail segments <NUM> in one of the rows of rail segments <NUM>. Since the fastener <NUM> is useful as a self-mating fastener, the posts generally have a height that is no greater than a height of the rail segments. In the embodiment illustrated in <FIG>, and <FIG>, the height Z3 of the posts <NUM> is less than the height Z1 of the rail segments <NUM>. In some embodiments, the height Z3 of posts <NUM> is up to <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> percent of the height Z1 of the rail segments <NUM>.

Posts useful in the fastener of the present disclosure may have a variety of cross-sectional shapes in a plane parallel to the backing. For example, the cross-sectional shape of the post may be a polygon (e.g., square, rectangle, rhombus, hexagon, pentagon, or dodecagon), which may be a regular polygon or not, or the cross-sectional shape of the post may be curved (e.g., round or elliptical). In some embodiments, the post has a base attached to the backing and a distal end, and the distal end has a cross-sectional area that is less than or equal to a cross-sectional area of the base. The post may taper from its base to its distal end, but this is not a requirement. In some embodiments, the post has a distal cap with a cap width that is greater than the width of the base. The cap can overhang the base on opposing sides or may overhang the base on all sides. Capped posts useful in the fastener of the present disclosure can have a variety of useful shapes including a mushroom (e.g., with a circular or oval head enlarged with respect to the stem), a nail, a T, or a golf tee.

Referring again to <FIG>, and <FIG>, in some embodiments, posts <NUM> useful in the fastener of the present disclosure have a maximum width X2 of up to about <NUM>, <NUM>, <NUM>, or <NUM> and a minimum width of at least <NUM>, <NUM>, or <NUM>. Some useful widths X2 of the posts <NUM> are in a range from <NUM> to <NUM>, <NUM> to <NUM>, or <NUM> to <NUM>. In some embodiments, posts <NUM> useful in the fastener of the present disclosure have a maximum length Y2 of up to about <NUM>, <NUM>, <NUM>, or <NUM> and a minimum width of at least <NUM>, <NUM>, or <NUM>. Some useful widths Y2 of the post <NUM> are in a range from <NUM> to <NUM>, <NUM> to <NUM>, <NUM> to <NUM>, or <NUM> to <NUM>. In some embodiments, the distance Y4 between posts <NUM> in the direction parallel to the length (l) of the fastener <NUM> is up to about up to about <NUM> (in some embodiments, up to <NUM>, <NUM>, <NUM>, or <NUM>) mm and at least about <NUM>, <NUM>, or <NUM>. The distance Y4 between posts <NUM> can be in a range from <NUM> to <NUM>, <NUM> to <NUM>, or <NUM> to <NUM>.

For embodiments such as the embodiment illustrated in <FIG>, posts <NUM> that taper from their bases to their distal tips have a sloping face and a taper angle A2 between the sloping face and the backing <NUM>. In some embodiments, the taper angle A2 between the sloping face of the post <NUM> and the backing <NUM> is in a range from <NUM> degrees to <NUM> degrees, in some embodiments, in a range from <NUM> degrees to <NUM> degrees, <NUM> degrees to <NUM> degrees, <NUM> degrees to <NUM> degrees, <NUM> degrees to <NUM> degrees, <NUM> degrees to <NUM> degrees, or <NUM> degrees to <NUM> degrees.

In some embodiments, the posts <NUM> have a maximum height Z3 (above the backing <NUM>) of up to <NUM> millimeter (mm), <NUM>, or <NUM> and, in some embodiments, a minimum height of at least <NUM> or <NUM>. The height Z3 of the posts can be in a range from <NUM> to <NUM>, <NUM> to <NUM>, <NUM> to <NUM>, or <NUM> to <NUM>. In some embodiments, each of the posts has a height-to-width aspect ratio that is at least <NUM>:<NUM>, at least <NUM>:<NUM>, or at least <NUM>:<NUM>. In some embodiments, each of the posts has a height-to-length aspect ratio that is at least <NUM>:<NUM>, at least <NUM>:<NUM>, or at least <NUM>:<NUM>.

Another embodiment of a fastener according to the invention is shown in <FIG> and <FIG>. In this embodiment, the cap portion <NUM> of the rail segment <NUM> has a different shape than the cap portion <NUM> of the embodiment shown in <FIG>, and <FIG>. The features and dimensions of any of the embodiments described above for the fastener shown in <FIG>, and <FIG> can be used in combination with the fastener shown in <FIG> and <FIG> to provide corresponding embodiments.

Fastener <NUM> is useful as a self-mating fastener. As used herein, self-mating refers to fasteners in which fastening is accomplished by interengaging fastening elements of the same type (e.g., fastening heads). In some embodiments, self-mating refers to fasteners in which fastening is accomplished by interengaging fastening elements of identical shape. In some embodiments, self-mating refers to the ability for the fastener to engage with itself when it is in a folded configuration, for example, along an axis parallel to either the length (L) or width (W) of the fastener, referring to <FIG> and <FIG>. Two fastener members (e.g., first and second fastener members (<NUM>,<NUM>)), each having the structure shown in <FIG> and <FIG>, for example, can be fastened together in a self-mating engagement as shown in <FIG>. In some embodiments, a first self-mating fastener <NUM> is a fastener of the present disclosure as described above in any of its embodiments, and a second self-mating fastener may include the rail segments but not include the posts. In some embodiments, the first and second fastener members may be different embodiments of the fastener of the present disclosure. For example, the first self-mating fastener <NUM> may have a cap shape like that shown in <FIG> and a second self-mating fastener <NUM> may have a cap shape like that shown in <FIG>. In any of these embodiments, when the first and second fastener members <NUM>, <NUM> undergo fastening, the posts typically bend away from the rail segments while the cap portions of the rail segments of the first and second fastener members pass by each other as shown in <FIG>. The posts then return to their original positions after the first and second fastener members are fastened as shown in <FIG>.

In at least one embodiment, a featured side of the fastener (i.e., the side of the backing having posts and rails) has further an electrically conductive contact element including an electrically conductive layer disposed on at least a portion thereon. In one example, the electrically conductive layer is disposed over the entire featured surface such that the entire first side is conductive. The electrically conductive layer can be any metalized particle or conductive polymer. Methods of forming the electrically conductive layer include sputtering, electrolytic coating, an electrically conductive material (such as copper or tin) onto the posts, rails, and areas in-between on the featured side. When two fasteners that are coated with an electrically conductive material are fastened, then an electrical pathway is formed on the featured side from one fastener to another fastener.

Accordingly, in some embodiments, the posts have a lower bending stiffness than that of the rail segments. The bending stiffness k for small strain behavior is determined by the equation k=3EI/H, in which E is the modulus of the material making up the posts and the rail segments, H is the height of the posts or rail segments, and I=W<NUM>L/<NUM>, in which W is the width and L is the length of the posts or rail segments. In some embodiments, the length of the base portion of the rail segments is greater than a length of the posts. In these embodiments, when the width of the base portion and the width of the posts are similar, the bending stiffness of the rail segments will be higher than the bending stiffness of the posts. Referring again to <FIG>, the rows <NUM> of rail segments <NUM> can collectively have a higher bending stiffness than rows <NUM> of posts <NUM>. When there are more posts <NUM> in a row <NUM> of posts, the bending stiffness of the posts can be adjusted (e.g., by selection length or width) so that collectively the row <NUM> of posts <NUM> has less bending stiffness than a row <NUM> of rail segments <NUM>. The bending stiffness of each row of rail segments or posts can be determined by the number of rail segments or posts in each row and the bending stiffness of each of the rail segments or posts.

In some embodiments, the fastening system of the present disclosure is releasably fastenable. As used herein, the term "releasably fastenable" means that the fastener members can alternate between the fastened and unfastened configurations one or more times without destroying the functionality of the fastener. Typically and advantageously, the unique structure of the fastener of the present disclosure can allow for multiple cycles of fastening and unfastening without excessive plastic (i.e., irreversible) deformation of the engaging rail segments. For example, a comparative fastener that includes rail segments, but no posts can undergo fastening when the rail segments are pushed against and past one another for interlocking. The cap portions of the rail segments of comparative fastener exhibit a relative high degree of plastic (i.e., irreversible) deformation after such engagement as shown in <FIG>. The plastic deformation can limit the ability of the comparative fastener to be unfastened and refastened since the shape of the fastener is altered by the first and successive engagements. In contrast, in the fastening system of the present disclosure when the first and second fastener members undergo fastening, the posts undergo elastic deformation while the cap portions of the rail segments of the first and second fastener members pass by each other as shown in <FIG>. The cap portions of the rail segments of the fastener of the present disclosure exhibit a relative low degree of plastic (i.e., irreversible) deformation after engagement as shown in <FIG>.

Since fastener <NUM> illustrated in <FIG> is useful as a self-mating fastener, a shortest distance X8 between one of the posts <NUM> and one of the base portions <NUM> of the rail segments <NUM> in adjacent rows <NUM>, <NUM> is wide enough to allow the insertion of the cap portion <NUM> of the rail segments <NUM>. Distance X8 may be substantially the same as X4, as described above in any of the embodiment for X4. In some embodiments, distance X8 is within about <NUM>, <NUM>, or <NUM> percent of the cap width X4. In some embodiments, a ratio of the distance X8 to the width X1 of the base portion <NUM> is in a range from <NUM>:<NUM> to <NUM>:<NUM> or from <NUM>:<NUM> to <NUM>:<NUM>, or the ratio may be about <NUM>:<NUM>. Distances X3 and X5 between one of the post <NUM> and one of the cap portions <NUM> of the rail segments <NUM> in adjacent rows <NUM>, <NUM> is generally smaller than distance X8 since the cap width X4 is wider than the width of the base portion X1. Some useful distances X3 and X5 are in a range from <NUM> to <NUM>, <NUM> to <NUM>, <NUM> to <NUM>, or <NUM> to <NUM>. Distances X3 and X5 between a post <NUM> and two adjacent rows of the cap portions <NUM> of rail segments <NUM> need not be equal.

In some embodiments, when the first and second fastener members are fastened, they can slide relative to each other in a direction parallel to the length of the backing. This may be advantageous, for example, if the positioning of the first and second fastener members relative to each is not desirable when the first and second fastener members are initially fastened. To achieve a desirable positioning the first and second fastener members can be slid into place.

The first and second fastener members of a fastening system according to some embodiments of the present disclosure may or may not be connected together. In some embodiments, the first and second fastener members may be connected to two discrete substrates. In some embodiments, the first and second fastener members may be part of the same strip of material in which the first self-mating fastener is folded over to contact the second self-mating fastener.

In the fastener according to the present disclosure, the rail segments, posts, and at least a portion of the backing are integral (that is, generally formed at the same time as a unit, unitary). Fastening elements such as rail segments and upstanding posts on a backing can be made, for example, by feeding a thermoplastic material onto a continuously moving mold surface with cavities having the inverse shape of the fastening elements. The thermoplastic material can be passed between a nip formed by two rolls or a nip between a die face and roll surface, with at least one of the rolls having the cavities. Pressure provided by the nip forces the resin into the cavities. In some embodiments, a vacuum can be used to evacuate the cavities for easier filling of the cavities. The nip has a large enough gap such that a coherent backing is formed over the cavities. The backing may be formed with no holes therethrough. The mold surface and cavities can optionally be air or water cooled before stripping the integrally formed backing and fastening elements from the mold surface such as by a stripper roll.

Suitable mold surfaces for forming fastening elements on a backing include tool rolls such as those formed from a series of plates defining a plurality of cavities about its periphery including those described, for example, in <CIT>). Cavities may be formed in the plates by drilling or photoresist technology, for example. Other suitable tool rolls may include wire-wrapped rolls, which are disclosed along with their method of manufacturing, for example, in <CIT>). Another example of a method for forming a backing with upstanding fastening elements includes using a flexible mold belt defining an array of fastening element-shaped cavities as described in <CIT>). Yet other useful methods for forming a backing with upstanding fastening elements can be found in <CIT>), <CIT>), and<CIT>).

If rail segments formed upon exiting the cavities do not have caps, first and second fastener members will not have any closure affinity for each other. Caps can be subsequently formed on the rail segments by a capping method as described in <CIT>). Typically, the capping method includes deforming the tip portions of the rail segments using heat and/or pressure. The heat and pressure, if both are used, could be applied sequentially or simultaneously. The formation of rail segments can also include a step in which the shape of the cap is changed, for example, as described in <CIT>) and/or <CIT>). For example, one or more of these processes can be useful for changing the shape of the cap portion <NUM> shown in <FIG> to the shape shown in <FIG>. The formation of rail segments can also include a step in which the cap is embossed, for example, as described in <CIT>). After one or more of these capping processes, first and second fastener members in a fastening system of the present disclosure can be closed together. The amount of force necessary to close and to peel open the first and second fastener members can be adjusted as desired by tailoring the capping process.

Another useful method for fastening elements on a backing is profile extrusion described, for example, in <CIT>). Typically, in this method a thermoplastic flow stream is passed through a patterned die lip (e.g., cut by electron discharge machining) to form a web having downweb ridges, slicing the ridges, and stretching the web to form separated fastening elements. The ridges may be considered precursors to the fastening elements and exhibit the cross-sectional shape of the rail segments and posts to be formed. The ridges are transversely sliced at spaced locations along the extension of the ridges to form discrete portions of the ridges having lengths in the direction of the ridges essentially corresponding to the length of the fastening elements to be formed. Stretching the backing so that it plastically deforms results in the separation of the fastening elements. In at least one embodiment, slicing the ridges or stretching the web can be optional and result in continuous rail elements and posts.

The fastener of the present disclosure may be made from a variety of suitable materials, including thermoplastics. Examples of thermoplastic materials suitable for making the fastener using the methods described above include polyolefin homopolymers such as polyethylene and polypropylene, copolymers of ethylene, propylene and/or butylene; copolymers containing ethylene such as ethylene vinyl acetate and ethylene acrylic acid; polyesters such as poly(ethylene terephthalate), polyethylene butyrate, and polyethylene napthalate; polyamides such as poly(hexamethylene adipamide); polyurethanes; polycarbonates; poly(vinyl alcohol); ketones such as polyetheretherketone; polyphenylene sulfide; and mixtures thereof. In some embodiments, the thermoplastic useful for making the fastener comprises at least one of a polyolefin, a polyamide, or a polyester. In some embodiments, the thermoplastic useful for making the fastener is a polyolefin (e.g., polyethylene, polypropylene, polybutylene, ethylene copolymers, propylene copolymers, butylene copolymers, and copolymers and blends of these materials). In some embodiments, the fastener of the present disclosure is made from a blend of any of these thermoplastic materials and an elastomer. Examples of elastomers useful in such tie layers include elastomers such as ABA block copolymers (e.g., in which the A blocks are polystyrenic and formed predominantly of substituted (e.g., alkylated) or unsubstituted moieties and the B blocks are formed predominately from conjugated dienes (e.g., isoprene and <NUM>,<NUM>-butadiene), which may be hydrogenated), polyurethane elastomers, polyolefin elastomers (e.g., metallocene polyolefin elastomers), olefin block copolymers, polyamide elastomers, ethylene vinyl acetate elastomers, and polyester elastomers. Examples of useful polyolefin elastomers include an ethylene propylene elastomer, an ethylene octene elastomer, an ethylene propylene diene elastomer, an ethylene propylene octene elastomer, polybutadiene, a butadiene copolymer, polybutene, or a combination thereof. Elastomers are available from a variety of commercial sources as described below. Any of these elastomers may be present in a blend with any of the thermoplastics in an amount of up to <NUM>, <NUM>, or <NUM> percent by weight.

The backing of the fastener of the present disclosure may have a variety of thicknesses. In some embodiments, including the embodiments illustrated in <FIG> and <FIG>, the thickness (Z4-Z5) of the backing <NUM> integral with the rail segments <NUM> and posts <NUM> may be up to about <NUM> micrometers (µm), <NUM> micrometers, or <NUM> micrometers and at least about <NUM> micrometers or <NUM> micrometers. This thickness does not include the heights of the rail segments and posts protruding from the first major surface of the backing. In some embodiments, the thickness of the thermoplastic backing is in a range from <NUM> to about <NUM> micrometers, from about <NUM> to about <NUM> micrometers, or from about <NUM> to about <NUM> micrometers.

In some embodiments, including the embodiments illustrated in <FIG> and <FIG>, the rows of rail segments <NUM> and rows of posts <NUM> are each independently formed on fillets <NUM>. Referring to <FIG>, the fillet thickness Z6 above the backing <NUM> may be up to about <NUM> micrometers (µm), <NUM> micrometers, or <NUM> micrometers and at least about <NUM> micrometers or <NUM> micrometers. This thickness does not include the heights of the rail segments and posts protruding from the first major surface of the backing. In some embodiments, the fillet thickness Z6 is in a range from <NUM> to about <NUM> micrometers, from about <NUM> to about <NUM> micrometers, or from about <NUM> to about <NUM> micrometers. In some embodiments, the backing, excluding the rail segments, posts, and fillets, is substantially uniform in thickness. For a thermoplastic that is substantially uniform in thickness, a difference in thickness between any two points in the backing may be up <NUM>, <NUM>, or <NUM> percent.

In at least one embodiment, rail segments on the first surface of the backing may have a density of at least <NUM> per square centimeter (cm<NUM>) (<NUM> per square inch in<NUM>). For example, the density of the rail segments may be at least <NUM>/cm<NUM> (<NUM>/in<NUM>), <NUM>/cm<NUM> (<NUM>/in<NUM>), <NUM>/cm<NUM> (<NUM>/in<NUM>), or <NUM>/cm<NUM> (<NUM>/in<NUM>). In some embodiments, the density of the rail segments may be up to <NUM>/cm<NUM> (<NUM>/in<NUM>), up to about <NUM>/cm<NUM> (<NUM>/in<NUM>), or up to about <NUM>/cm<NUM> (<NUM>/in<NUM>). Densities in a range from <NUM>/cm<NUM> (<NUM>/in<NUM>) to <NUM>/cm<NUM> (<NUM>/in<NUM>) or <NUM>/cm<NUM> (<NUM>/in<NUM>) to <NUM>/cm<NUM> (<NUM>/in<NUM>) may be useful, for example. The density of the rail segments is related to the distance between rail segments X7, measured as the center-to-center distance of the rail segments in adjacent rows as shown in <FIG>. A variety of distances X7 between rows of rail segments can be useful. In some embodiments, the distance X7 between rows of rail segments is <NUM> to <NUM>, <NUM> to <NUM>, or <NUM> to <NUM>. The spacing of the rows of rail segments and the posts need not be uniform.

In some embodiments, the backing can be monoaxially or biaxially stretched. Stretching in the machine direction can be carried out on a continuous web of the backing, for example, by directing the web over rolls of increasing speed. Stretching in a cross-machine direction can be carried out on a continuous web using, for example, diverging rails or diverging disks. A versatile stretching method that allows for monoaxial and sequential biaxial stretching of the thermoplastic layer employs a flat film tenter apparatus. Such an apparatus grasps the thermoplastic layer using a plurality of clips, grippers, or other film edge-grasping means along opposing edges of the thermoplastic web in such a way that monoaxial and biaxial stretching in the desired direction is obtained by propelling the grasping means at varying speeds along divergent rails. Increasing clip speed in the machine direction generally results in machine-direction stretching. Stretching at angles to the machine direction and cross-direction are also possible with a flat film tenter apparatus. Monoaxial and biaxial stretching can also be accomplished, for example, by the methods and apparatus disclosed in <CIT>) and the references cited therein. Flat film tenter stretching apparatuses are commercially available, for example, from Brückner Maschinenbau GmbH, Siegsdorf, Germany.

In some embodiments, after stretching, the backing has an average thickness of up to <NUM>, <NUM>, <NUM>, <NUM>, or <NUM>. In some embodiments, the average thickness of the backing after stretching is in a range from <NUM> to <NUM>, <NUM> to <NUM>, or <NUM> to <NUM>. In general, the backing has no through-holes before or after stretching. However, in various embodiments, a pocket in the film with the tooling elements can utilize a flame opening operation where an open flame is applied to the closed end causing the pocket to open, resulting in through-holes.

In some embodiments, the density of the rail segments and/or posts after stretching may be up to about <NUM>/cm<NUM> (<NUM>/in<NUM>) or up to about <NUM>/cm<NUM> (<NUM>/in<NUM>). Densities after stretching in a range from <NUM>/cm<NUM> (<NUM>/in<NUM>) to <NUM>/cm<NUM> (<NUM>/in<NUM>), <NUM>/cm<NUM> (<NUM>/in<NUM>) to <NUM>/cm<NUM> (<NUM>/in<NUM>), <NUM>/cm<NUM> (<NUM>/in<NUM>) to <NUM>/cm<NUM> (<NUM>/in<NUM>), or <NUM>/cm<NUM> (<NUM>/in<NUM>) to <NUM>/cm<NUM> (<NUM>/in<NUM>) may be useful, for example. Again, the spacing of the spacing of the rows of rail segments and the posts need not be uniform.

In some embodiments, the backing includes a multi-layer construction. The multilayer construction can include from <NUM> to <NUM>, <NUM> to <NUM>, or <NUM> to <NUM> layers. The multiple layers can include films, adhesives, and tie layers. The multiple layers can be joined together using a variety of methods including coating, adhesive bonding, and extrusion lamination. In some embodiments, the backing having the protruding rail segments and posts can be made (e.g., using any of the methods described above) from a multilayer melt stream of thermoplastic materials. This can result in the protruding rail segments and posts formed at least partially from a different thermoplastic material than the one predominately forming the backing. Various configurations of upstanding posts made from a multilayer melt stream are shown in <CIT>), for example. In some embodiments, the thickness of the backing (including a multi-layer backing) combined with the height of the rail segments is up to <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> micrometers. In some embodiments, the thickness of the fastening system according to the present disclosure, in which the first and second fastener members are engaged with each other is up to <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> micrometers.

The bending stiffness of the fastener (e.g., at an axis parallel to the width of the fastener) is influenced by the modulus of the material or materials making up the backing, the thickness of the layer or layers making up the backing, the distance between the structures (including rail segments and posts) on the backing, and the dimension of the fastener in a parallel to the bending axis. In general, materials, thicknesses of the layer or layers in the fastener, and distances between structures can be selected to provide the fastener with a desirable bending stiffness. Advantageously, in many embodiments of the fastener of the present disclosure, the bending stiffness of the fastener is low enough such that the fastener does not unintentionally open when the fastener is bent. In some of these embodiments, the bending stiffness of the fastener in a closed configuration is in a range from <NUM> mN/mm to <NUM> mN/mm, <NUM> mN/mm to <NUM> mN/mm, or <NUM> mN/mm to <NUM> mN/mm as measured by a Flexural Stiffness Test Method, for example, as described in the Examples, below.

In some embodiments, the fastener of the present disclosure and/or the backing of the fastener includes a tie layer. Tie layers can include elastomeric materials or other materials that have lower melting points than the backing integral with the rail segments and posts. Examples of elastomers useful in such tie layers include elastomers such as ABA block copolymers (e.g., in which the A blocks are polystyrenic and formed predominantly of substituted (e.g., alkylated) or unsubstituted moieties and the B blocks are formed predominately from conjugated dienes (e.g., isoprene and <NUM>,<NUM>-butadiene), which may be hydrogenated), polyurethane elastomers, polyolefin elastomers (e.g., metallocene polyolefin elastomers), olefin block copolymers, polyamide elastomers, ethylene vinyl acetate elastomers, and polyester elastomers. Examples of useful polyolefin elastomers include an ethylene propylene elastomer, an ethylene octene elastomer, an ethylene propylene diene elastomer, an ethylene propylene octene elastomer, polybutadiene, a butadiene copolymer, polybutene, or a combination thereof. Various elastomeric polymers and other polymers may be blended to have varying degrees of elastomeric properties. For example, any of these elastomeric materials may be present in a range from <NUM>% by weight to <NUM>% by weight in a blend with any of the thermoplastics described above for forming the backing integral with the rail segments and posts.

Many types of elastomers are commercially available, including those from BASF, Florham Park, N. , under the trade designation "STYROFLEX", from Kraton Polymers, Houston, Tex. , under the trade designation "KRATON", from Dow Chemical, Midland, Mich. , under the trade designation "PELLETHANE", "INFUSE", VERSIFY", "NORDEL", and "ENGAGE", from DSM, Heerlen, Netherlands, under the trade designation "ARNITEL", from E. duPont de Nemours and Company, Wilmington, Del. , under the trade designation "HYTREL", from ExxonMobil, Irving, Tex. under the trade designation "VISTAMAXX", and more.

In some embodiments, the fastener of the present disclosure and/or the backing of the fastener includes a layer of a hot melt adhesive. Hot melt adhesives are typically nontacky at room temperature and use of hot melts can decrease contamination on equipment during the handling of the film and lamination. Suitable hot melt adhesives include those based on ethylene-vinyl acetate copolymers, ethylene-acrylate copolymers, polyolefins, polyamides, polyesters, polyurethanes, styrene block copolymers, polycaprolactone, and polycarbonates and may include a variety of tackifying resins, plasticizers, pigments, fillers, and stabilizers. Examples of suitable hot melt adhesives include those available from <NUM> Company, St. Paul, Minn. , under the trade designation "<NUM> SCOTCH-WELD" hot melt adhesives (e.g., products <NUM> B and <NUM> PG). In at least one embodiment, the adhesive can be electrically conductive.

<FIG> illustrates a self-mating fastener <NUM> that is similar in structure and configuration to the fastener <NUM> described herein except self-mating fastener <NUM> is at least partially electrically conductive and has contact elements disposed on a portion of the self-mating fastener. As shown in self-mating fastener <NUM>, the contact elements include electrically conductive layers disposed on portions of rail elements and backing <NUM>. In at least one embodiment, the contact elements include only electrically conductive layers or conductive stakes on the first side <NUM>. In another embodiment, the contact elements include all electrically conductive layers, and conductive stakes.

The self-mating fastener <NUM> comprises a first side <NUM>, and a second side <NUM>. The first side <NUM> has fastener elements protruding distally from a backing <NUM>. The second side <NUM> can be a side intended to engage with a target surface, such as skin, first electronic device, etc. The second side <NUM> can also have an optional electrically conductive layer <NUM> disposed thereon. For example, the electrically conductive layer <NUM> can be configured to maintain an electrical pathway with the underlying target surface, e.g., a skin surface or electronic device. In at least one embodiment electrically conductive layer <NUM> is non-continuous. For example, between electrically conductive layer <NUM> and electrically conductive layer <NUM> can be electrically insulative layer <NUM> which can electrically separate the electrically conductive layers.

The first side <NUM> includes a plurality of post elements (e.g., post element <NUM>, and post element <NUM>). The post elements can be arranged as a row of individual posts. For example, post element <NUM> can include post <NUM> and post element <NUM> can include post <NUM>. The first side <NUM> includes also a plurality of rail elements (e.g., rail element <NUM>, rail element <NUM>, and rail element <NUM>). Each rail element includes a plurality of rail segments arranged as a row. For example, rail element <NUM> can include rail segment <NUM>, rail element <NUM> can include rail segment <NUM>, and rail element <NUM> can include rail segment <NUM>.

The number of post elements or rail elements is variable, with a different possible configuration options and is shown only as an illustrative example. The post elements are shown in an alternating configuration with the rail elements. For example, post <NUM> is shown between rail segment <NUM> and rail segment <NUM>. Post <NUM> is shown between rail segment <NUM>, and rail segment <NUM>. In not claimed embodiments, the post elements can be optional as configurations exist utilizing only a plurality of rail elements.

In at least one embodiment, portions of the plurality of rail elements and/or the plurality of post elements can have at least one electrically conductive layer disposed thereon. For example, the cap portions, and part of the base portion of the rail elements can have the electrically conductive layer disposed thereon, e.g., for the cap portion <NUM>, electrically conductive layer <NUM>; for the cap portion <NUM>, electrically conductive layer <NUM>; and for the cap portion <NUM>, electrically conductive layer <NUM>. In at least one embodiment, the electrically conductive layer can be disposed on a top surface of the cap portion. The electrically conductive layer can cover at least part of the total top surface area or even the entire top surface of the cap portion.

The first side <NUM> of the backing <NUM> can have one or more electrically conductive layers disposed between the plurality of rail elements and/or plurality of post elements. For example, electrically conductive layer <NUM> can be disposed on the backing <NUM> (first side <NUM>) adjacent to rail element <NUM> and also be disposed on an adjacent base portion <NUM> of rail segment <NUM>. In another example, electrically conductive layer <NUM> can be disposed on the first side <NUM> between post element <NUM> and rail element <NUM>. For example, the electrically conductive layer <NUM> can be disposed on the first side <NUM> to the right of the rail element <NUM>. The electrically conductive layer can extend continuously in the longitudinal direction in a linear manner and be disjoined with other electrically conductive layers (e.g., electrically conductive layer <NUM>, and electrically conductive layer <NUM>) along the width.

The electrically conductive layer <NUM> can extend from the base portion <NUM> to a base portion <NUM> of the post <NUM>. An electrically conductive layer disposed on the backing <NUM> can have a non-uniform thickness. Further, the electrically conductive layer between a base portion and the backing <NUM> can have a corner radius of no greater than <NUM>, no greater than <NUM>. In at least one embodiment, the electrically conductive layers can be applied via vapor deposition or sputtering.

In at least one embodiment, the base portion of a post or post element can be defined as at least one-quarter of the height Z3 of a post element. For example, the base portion <NUM> can be at least one-quarter of the height Z3 of post <NUM>. The base portion of a rail element can be defined by a dimension Z2 which is up to a cap portion.

In at least one embodiment, at least one of the rail elements in the self-mating fastener <NUM> can include a conductive stake therethrough. The conductive stake can penetrate the rail element or rail segment and be approximately centered on the base portion of the rail element. For example, conductive stake <NUM> can penetrate both the cap portion <NUM> and the base portion <NUM> such that the conductive stake <NUM> forms a conductive path from the electrically conductive layer <NUM> to the electrically conductive layer <NUM> of the second side <NUM>.

Likewise, the conductive stake <NUM> can penetrate the cap portion <NUM> and the base portion <NUM> through the electrically conductive layer <NUM> of the backing <NUM> to form a conductive path from the electrically conductive layer <NUM> to the electrically conductive layer <NUM>. In at least one embodiment, the conductive stake can be a rigid element that is electrically conductive. The conductive stake can also be a rail element having a cap portion, and/or a base portion that is electrically conductive. For example, the conductive stake can be a polymer having metalized particles embedded and integrally formed with the rail element such that the cap portion and the second side form an electrical pathway.

In at least one embodiment, electrically conductive layer <NUM>, conductive stake <NUM>, electrically conductive layer <NUM> form a first electrical pathway. In at least one embodiment, electrically conductive layer <NUM>, conductive stake <NUM> and electrically conductive layer <NUM> can form a second electrical pathway. In at least one embodiment, electrically conductive layer <NUM>, electrically conductive layer <NUM>, and conductive stake <NUM> can form a third electrical pathway. In at least one embodiment, electrically conductive layer <NUM> can be extended to cover the entire second side <NUM> of the backing <NUM>, then electrically conductive layer <NUM>, electrically conductive layer <NUM>, and electrically conductive layer <NUM>.

In at least one embodiment, electrically conductive layer <NUM> and electrically conductive layer <NUM> are separated by electrically insulative layer <NUM>. Electrically insulative layer <NUM> can exist as a separate layer or can be integrated with the backing <NUM> itself, e.g., if the backing <NUM> can be formed from an electrically insulative material making electrically insulative layer <NUM> integral with the backing <NUM>. In at least one embodiment, the electrically conductive layer <NUM> can be electrically distinct from electrically insulative layer <NUM> and electrically conductive layer <NUM>. For example, electrically conductive layer <NUM> can be formed from a different material than electrically conductive layer <NUM> which would give electrically conductive layer <NUM> different electrical properties suitable for different electrical applications. The electrically insulative layer <NUM> can be arranged in the longitudinal direction and alternate with the electrically conductive layer <NUM> and electrically conductive layer <NUM>. In at least one embodiment, electrically conductive layer <NUM> can be aligned with a rail element <NUM> (as described in <FIG>).

In at least one embodiment, the conductive stake is optional. Electrically conductive layer <NUM> can form a different and separate electrical pathway.

In at least one embodiment, the electrically conductive layer adjacent to a rail segment with a conductive stake, e.g., electrically conductive layer <NUM>, can also be electrically coupled to the top of the cap portion, e.g., electrically conductive layer <NUM>. This can facilitate an electrical connection from the second side <NUM> of self-mating fastener <NUM> to a second side of another self-mating fastener. Examples of electrical coupling can include a second conductive stake through the backing <NUM> or base portion <NUM> such that the electrically conductive layer <NUM> forms an electrical pathway to electrically conductive layer <NUM>.

<FIG> illustrates a different view of the self-mating fastener <NUM>. The self-mating fastener <NUM> comprises a post <NUM>, a rail segment <NUM>, an electrically conductive layer <NUM>, an electrically conductive layer <NUM>, an electrically insulative layer <NUM>, and an electrically conductive layer <NUM>. As shown, the electrically conductive layer <NUM> extends continuously in the longitudinal direction except for the portions of electrically conductive layer <NUM> that extend onto the base portion of the rail segment <NUM>. In at least one embodiment, each cap portion of a rail segment can have its own electrically conductive layer. For example, electrically conductive layer <NUM> can be different from an electrically conductive layer for a different rail segment in rail element <NUM>. In at least one embodiment, the electrically conductive layer <NUM> can be continuous in the longitudinal direction or can also be segmented based on the proximity to the rail segment. As shown herein, the rail element <NUM> extends in the longitudinal direction and is alternating with the post element <NUM> in the width dimension.

<FIG> illustrates a fastening system <NUM> that includes a self-mating fastener <NUM> as described in <FIG> and a second self-mating fastener <NUM>. The second self-mating fastener <NUM> is configured similarly to self-mating fastener <NUM>.

For example, the second self-mating fastener <NUM> includes a backing <NUM>. The backing <NUM> can have a first side <NUM> and a second side <NUM>. An electrically conductive layer <NUM> can be disposed on the second side <NUM>. Although not shown, the backing <NUM> can also have an electrically insulative layer disposed thereon outside the region of the electrically conductive layer <NUM>. The backing <NUM> can have a plurality of features extending from the first side <NUM>. For example, the backing <NUM> can have a post element <NUM>, a rail element <NUM>, a post element <NUM>, and a rail element <NUM> arranged in an alternating fashion. As shown, only some of the rail elements have conductive stakes inserted therethrough. For example, rail element <NUM> can have a conductive stake <NUM> inserted and centered through the base portion <NUM> and the cap portion <NUM>. The conductive stake <NUM> can contact the electrically conductive layer <NUM> disposed on a top surface of the cap portion <NUM>. In at least one embodiment, the rail elements and post element can be continuous along the longitudinal direction (unlike the rows of rail segments and posts described in self-mating fastener <NUM>).

In at least one embodiment, electrically conductive layers can be disposed on the first side <NUM> between the rail element and/or post element. For example, electrically conductive layer <NUM> can be adjacent to rail element <NUM> and electrically conductive layer <NUM> can be adjacent to rail element <NUM> similar to self-mating fastener <NUM> in <FIG>. In at least one embodiment, the electrically conductive layer <NUM> can be disposed on a top surface of the cap portion <NUM>.

As a system, the self-mating fastener <NUM> can be slidable (e.g., in the longitudinal direction) with respect to second self-mating fastener <NUM> while maintaining an electrical connection between, e.g., electrically conductive layer <NUM> and electrically conductive layer <NUM>; electrically conductive layer <NUM> and electrically conductive layer <NUM>; electrically conductive layer <NUM> and electrically conductive layer <NUM>; and electrically conductive layer <NUM> and electrically conductive layer <NUM>.

The fastening system <NUM> can have a plurality of electrical pathways. In electrical pathway <NUM>, if the electrically conductive layer <NUM> is electrically coupled to the conductive stake <NUM>, then electrically conductive layer <NUM> can be electrically coupled to electrically conductive layer <NUM> and form a ground electrical connection. Alternatively, in electrical pathway <NUM>, the electrically conductive layer <NUM>, conductive stake <NUM>, electrically conductive layer <NUM>, conductive stake <NUM>, and electrically conductive layer <NUM> are electrically coupled. In electrical pathway <NUM>, the electrically conductive layer <NUM> can contact electrically conductive layer <NUM> to form a longitudinal conductive path from electrically conductive layer <NUM> to electrically conductive layer <NUM>. In an electrical pathway <NUM>, the electrically conductive layer <NUM> can contact electrically conductive layer <NUM> to form a longitudinal conductive path.

In at least one embodiment, the self-mating fasteners of fastening system <NUM> can be formed from the same methods as described for fastener <NUM> in <FIG>.

<FIG> illustrates a top view of the fastening system <NUM> shown with the second self-mating fastener <NUM> movable about the longitudinal direction but not the width dimension. The rail element <NUM> is electrically coupled to the electrically conductive layer <NUM> and mechanically coupled to rail element <NUM> (including rail segment <NUM>). The rail element <NUM> is electrically coupled to the electrically conductive layer <NUM> and mechanically coupled to the rail element <NUM> (including rail segment <NUM>). The self-mating fastener <NUM> has a plurality of rows (shown are three rows including rail element <NUM>, post element <NUM>, and rail element <NUM> arranged across the width dimension).

In at least one embodiment, an electrically conductive layer can be disposed as a continuous layer (without interruption) along the longitudinal direction. Thus, the self-mating fastener <NUM> will have rows of longitudinally disposed electrically conductive strips made of the electrically conductive layer. For example, electrically conductive layer <NUM> can be disposed between rail segment <NUM> and another rail element in the rail element <NUM>. In at least one embodiment, at least one rail element in the row of rail elements can have a conductive stake such that there is an electrical connection between a device attached to the conductive stake and an electrically conductive layer.

<FIG> illustrates an embodiment of a fastening system <NUM> that includes a self-mating fastener <NUM>, and self-mating fastener <NUM>. In at least one embodiment, the contact element is a separate feature extending from the backing. The self-mating fastener <NUM> can have rail element <NUM>, contact element <NUM>, and post element <NUM> extending from backing <NUM>. The self-mating fastener <NUM> can have a post element <NUM>, contact element <NUM>, and rail element <NUM> extending from backing <NUM>. In at least one embodiment, both post elements can be I-shaped throughout the length of the post element and both rail elements can be T-shaped throughout the length of the rail element.

One difference between self-mating fastener <NUM> and the self-mating fastener <NUM> described herein is that the rail elements and post elements are continuous in the longitudinal direction with no breaks in the width dimension. In at least one embodiment, the backing <NUM> can be non-uniform and have multiple segments that extend continuously in longitudinal direction and differ in the width dimension. For example, a plurality of backing segments including backing segment <NUM> can form the backing <NUM>. The backing segment <NUM> can be different from backing <NUM> with different electrical properties. In at least one embodiment, the contact element <NUM> can be disposed on a backing segment <NUM>. In another example, the post element <NUM>, the contact element <NUM>, and the rail element <NUM> can each extend from a separate backing segment and may be joined together to form the backing <NUM>.

In at least one example, contact element <NUM> can be formed from an electrically conductive material and have an electrically conductive material as the backing segment <NUM> while backing <NUM> is formed from an electrically insulative material. Thus, the backing <NUM> can have an electrically conductive material adjacent to non-electrically conductive material. In at least one embodiment, each backing can be formed using (profile) extrusion and joined together using bonding techniques as described in <CIT>.

In at least one embodiment, the electrically conductive material is extrudable or able to be deposited on a polymeric substance. Examples can include metals, metal polymer compositions, carbon black polymer compositions, conductive polymers such as polyaniline-ES, polyaniline-EB, polyaniline-LS, trans-polyacetylene, poly (p-phenylene), poly(<NUM>-vinylperlene), polypyrrole, poly(<NUM>,<NUM>-bis(<NUM>-tetradecylthiophene-<NUM>-yl)thieno[<NUM>,<NUM>-b]thiophene), poly(<NUM>-(<NUM>-thienyyloxy)ethanesulfonate), polythiophene, or combinations thereof using various dopants and acid combinations.

In at least one embodiment, rail element <NUM> can engage with another rail element <NUM> at the bottom of the T-shape on one side and, with the post element <NUM> on the side of the T-shape. This can allow the self-mating fastener <NUM> to be slidable along the longitudinal direction with respect to self-mating fastener <NUM>.

For self-mating fastener <NUM>, the contact element <NUM> is shown having an arc-shape <NUM>. Arc-shapes as referred to herein can refer to a partial arc-shape (as shown in arc-shape <NUM> or arc-shape <NUM>) or an arch (as described in <FIG>). The contact element <NUM> can have a first base portion <NUM> attached to backing segment <NUM>. Extending distally from the backing segment <NUM> is distal end <NUM>. The distal end <NUM> can be offset from the first base portion <NUM>. For example, the distal end <NUM> can be unaligned with the first base portion <NUM> along an axis parallel to first axis <NUM>. The first axis <NUM> can extend perpendicularly from the plane of the backing <NUM>.

The arc-shape <NUM> can include an inner surface <NUM> and an outer surface <NUM>. The arcuate dimension of the section the inner surface <NUM> is less than the arcuate dimension of a section of the outer surface <NUM>. For example, the surface area of the inner surface <NUM> is less than the surface area of the outer surface <NUM> for the same length of contact element <NUM>. A resistive force <NUM>, when applied to the contact element <NUM> toward the backing segment <NUM> and along first axis <NUM> can cause the contact element <NUM> to spring back.

For self-mating fastener <NUM>, the contact element <NUM> is shown having an arc-shape <NUM> similar to contact element <NUM>. The contact element <NUM> can have a first base portion <NUM> attached to backing <NUM>. Extending distally from the backing <NUM> is distal end <NUM>. The distal end <NUM> can be offset from the first base portion <NUM>.

The arc-shape <NUM> can include an inner surface <NUM> and an outer surface <NUM>. The dimension of the section the inner surface <NUM> is less than the dimension of a section of the outer surface <NUM>. For example, the surface area of the inner surface <NUM> is less than the surface area of the outer surface <NUM> for the same length of contact element <NUM>. A resistive force <NUM>, when applied to contact element <NUM> toward the backing <NUM> along first axis <NUM> can cause the contact element <NUM> to spring back.

The contact element <NUM> can be configured to contact the contact element <NUM>. Both contact elements can have a shape that allows a resistive force in the thickness dimension such that a contact element springs back when downward pressure is applied. The contact elements can be facing the same direction or the opposite direction. For example, contact element <NUM> is shown with the distal end <NUM> oriented toward the left (vs the first base portion <NUM> and relative to rail element <NUM> when features are pointed upwards) and contact element <NUM> is shown with the distal end <NUM> oriented toward the left (vs. First base portion <NUM> and relative to rail element <NUM>). In at least one embodiment, the distal end <NUM> can be oriented in the same direction as distal end <NUM> when the two self-mating fasteners are mated forming a side A-shape.

In at least one embodiment, the outer surface <NUM> of the distal end <NUM> can contact the outer surface <NUM> of distal end <NUM> such that the resistive force of either contact element <NUM> or contact element <NUM> causes each contact element to maintain contact when rail element <NUM> mates with rail element <NUM>. In at least one embodiment, the inner surface <NUM> can contact the inner surface <NUM> when rail element <NUM> is mated with rail element <NUM>. The contact elements can be slidable in the longitudinal direction with respect to each other.

Although shown as continuous rails in the longitudinal direction, the rail elements and post elements can be segmented as shown in <FIG> and <FIG>. The contact elements can be configured to be continuous such that the conductive path is formed from one end to another end longitudinally in the longitudinal direction.

<FIG> illustrates another embodiment of a fastening system having different self-mating fasteners. The fastening system <NUM> can be configured like the fastening system <NUM> except having different contact elements. For example, the fastening system <NUM> can include a self-mating fastener <NUM>, and a self-mating fastener <NUM>. The self-mating fastener <NUM> can include a backing <NUM> and the self-mating fastener <NUM> can include backing <NUM>. A contact element <NUM> can extend from the backing <NUM> and contact element <NUM> can extend from the backing <NUM>.

The contact element <NUM> and contact element <NUM> can be shaped like an (complete) arch extending from the backing <NUM> and backing <NUM>. The contact element <NUM> can include first base portion <NUM> and second base portion <NUM> and the contact element <NUM> can include first base portion <NUM> and second base portion <NUM>. The first base portion <NUM> is spaced apart from second base portion <NUM>. The walls of the contact element <NUM> can extend distally and converge to a distal end <NUM> forming a vertex <NUM>. Similarly, the walls of the contact element <NUM> can extend distally and converge to a distal end <NUM> forming vertex <NUM>. The walls of the contact element <NUM> and contact element <NUM> can form a tube <NUM> and tube <NUM>. The tube <NUM> can fully encapsulate a space. In at least one embodiment, the tube <NUM> can be configured to transport or filled with fluids (such as medicament, saline, air, nitrogen, oxygen, water, or biological fluids such as blood or insulin) in the longitudinal direction. Similar to contact element <NUM>, the contact element <NUM> and contact element <NUM> can provide a spring back force in response to a resistive force from the distal end towards the backing.

When the self-mating fastener <NUM> is mated with self-mating fastener <NUM>, the rail element <NUM> from self-mating fastener <NUM> can interlock with rail element <NUM> on self-mating fastener <NUM>. The contact element <NUM> or contact element <NUM> can be of a height that allows contact and a resistive force with respect to contact element <NUM> or contact element <NUM>.

In at least one embodiment, the contact element of fastening system <NUM> or fastening system <NUM> can have a height from the base to the distal end greater than the Z2 dimension described in <FIG>. In at least one embodiment, the contact element (either the arc of contact element <NUM> and contact element <NUM> from <FIG> or the vertex of contact element <NUM> and contact element <NUM>) can have a height from the backing surface to outer surface of the vertex or distal end that is at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, or at least <NUM>% that of the Z2 dimension described in <FIG>. The self-mating fastener <NUM> can be formed in segments as described in <FIG>. For example, the self-mating fastener <NUM> can have one or more backing segments that are formed using profile extrusion and joined together.

<FIG> illustrates an overview of an electronic system <NUM>. The electronic system <NUM> comprises a mammalian subject <NUM>, a fastening system <NUM>, and one or more electronic devices such as first electronic device <NUM>. The fastening system <NUM> can include any combination of the self-mating fasteners described herein. For example, fastening system <NUM> can refer to the self-mating fastener <NUM> paired with the self-mating fastener <NUM>. The self-mating fastener can include various adhesives or mechanical engagements to releasably attach a backing of the self-mating fastener to the mammalian subject <NUM>.

In at least one embodiment, the backing can attach to the first electronic device <NUM> and the contact elements of a first self-mating fastener can contact the contact elements of a second self-mating fastener. The backing of the second self-mating fastener can be attached to the skin of the mammalian subject <NUM>. Thus, a conductive path can be formed from the electronic device to the skin via the contact elements or from a first electronic device to a second electronic device via the contact elements.

<FIG> illustrates a more detailed view of the fastening system <NUM> described herein. The fastening system <NUM> can include a self-mating fastener <NUM>, a first electronic device <NUM>, and a second electronic device <NUM>. The self-mating fastener <NUM> can form a track such that first electronic device <NUM>, second electronic device <NUM>, or both are slidable <NUM> in the longitudinal direction when a self-mating fastener <NUM> is attached to the electronic device and the first electronic device <NUM> is electrically coupled to a portion of the self-mating fastener <NUM>.

As shown on <FIG>, the self-mating fastener <NUM> can have two sides, a first side <NUM> and a second side <NUM>. The first side <NUM> (having the rail element and the contact element) can face toward another self-mating fastener (e.g., self-mating fastener <NUM>). The second side <NUM> can be an unfeatured surface that has an adhesive <NUM> disposed thereon. In at least one embodiment, the adhesive <NUM> can be a skin compatible (pressure sensitive) adhesive that causes minimal irritation to the skin <NUM> such as silicone adhesives sold by <NUM> (Saint Paul, MN). The adhesive <NUM> can be optionally covered with a release liner until the self-mating fastener <NUM> is ready to be attached to the skin <NUM>. In at least one embodiment, the width <NUM> of the self-mating fastener <NUM> is at least that of the adhesive <NUM>. If grounded, a portion of the featured surface of the self-mating fastener <NUM> can be electrically coupled to the skin <NUM>.

In at least one embodiment, any portion of the backing or backing segment, the rail element, contact element, or post element of any of the fasteners described in this disclosure herein can be transparent or translucent so that the portion is configured to act as a light guide. Examples of construction and materials can be found in U. Patent Nos. <CIT><CIT> and <CIT>.

Light can be transmitted longitudinally through and along a rail element, contact element, or post element. In another example, the light can be directed toward the skin, i.e., along a perpendicular axis to the skin through the rail element, contact element, post element, and/or backing. In at least one embodiment, the adhesive <NUM> to attach the fastener <NUM> to the skin <NUM> can be optically clear.

The self-mating fastener <NUM> can attach to the first electronic device <NUM> via an adhesive <NUM>. In at least one embodiment, one or more features of the self-mating fastener <NUM> can electrically couple leads from the first electronic device <NUM> through the backing (e.g., via conductive stakes, or leads that penetrate the backing onto the contact element) and onto the featured surface of the self-mating fastener <NUM>. The self-mating fastener <NUM> can have a first side <NUM> (having a rail element and other features) and a second side <NUM> which is generally unfeatured. The self-mating fastener <NUM> can be configured such that the first electronic device <NUM> can form an electrical pathway from the first side <NUM> to the first electronic device <NUM>.

The first side <NUM> of the self-mating fastener <NUM> can face toward the first side <NUM> of the self-mating fastener <NUM> and mechanically engage with the rail elements and contact elements. Electrical signals can be transmitted from first electronic device <NUM> longitudinally through self-mating fastener <NUM> to second electronic device <NUM> via an electrical pathway. The width <NUM> of the first electronic device <NUM> can be at least the width of the self-mating fastener <NUM>. In at least one embodiment, the width <NUM> can be no greater than width <NUM>.

<FIG> illustrates an electronic system <NUM> similar to electronic system <NUM>. The electronic system <NUM> includes a plurality of self-mating fasteners disposed on a substrate (e.g., substrate <NUM>). Each self-mating fastener can have at least one contact element as described herein. The substrate <NUM> can be configured to be conformable to skin <NUM> and strong enough to support the self-mating fastener <NUM> or self-mating fastener <NUM> while adhered to the skin <NUM>.

The electronic system <NUM> shows a self-mating fastener <NUM> and self-mating fastener <NUM> disposed on substrate <NUM>. The substrate <NUM> can be a transparent medical dressing such as a hydrocolloid dressing. An example of the transparent medical dressing is commercially available under the trade designation Tegaderm from <NUM> (Saint Paul, MN). The self-mating fastener can be secured to the substrate <NUM> with an adhesive or can be formed therein.

In at least one embodiment, the substrate <NUM> has a first electronic device <NUM> secured thereon. In at least one embodiment, the first electronic device <NUM> can be secured to the substrate <NUM>. For example, the substrate <NUM> can be a printed circuit board.

The self-mating fastener <NUM> can mate with self-mating fastener <NUM>, and self-mating fastener <NUM> can mate with self-mating fastener <NUM>. Self-mating fastener <NUM> and self-mating fastener <NUM> can be disposed on substrate <NUM> such that substrate <NUM> can be slidable along a track formed by self-mating fastener <NUM> and self-mating fastener <NUM> in the longitudinal direction. The substrate <NUM> can be more rigid relative to substrate <NUM>. Further, electrical signals from the first electronic device <NUM> can be transmitted along self-mating fastener <NUM> and self-mating fastener <NUM> and also self-mating fastener <NUM> and self-mating fastener <NUM>.

In at least one embodiment, the substrate <NUM> can support a second electronic device or other substrates. For example, substrate <NUM> can have self-mating fastener <NUM> and self-mating fastener <NUM> disposed thereon. The self-mating fastener <NUM> and self-mating fastener <NUM> can be configured to mate with other self-mating fasteners on another substrate such that the substrates are stacked and movable relative to each other and form electrical connections sufficient to transmit electrical signals along electrical pathways.

The phrase "comprises at least one of" followed by a list refers to comprising any one of the items in the list and any combination of two or more items in the list. The phrase "at least one of" followed by a list refers to any one of the items in the list or any combination of two or more items in the list.

As used herein, the term "or" is generally employed in its usual sense unless the content clearly dictates otherwise.

The term "machine direction" (MD) as used herein denotes the direction of a running web of material during a manufacturing process. When a strip is cut from a continuous web, the dimension in the machine direction corresponds to the length "L" of the strip. The terms "machine direction" and "longitudinal direction" may be used interchangeably. The term "cross-machine direction" (CD) as used herein denotes the direction which is essentially perpendicular to the machine direction. When a strip is cut from a continuous web, the dimension in the cross-machine direction corresponds to the width "W" of the strip. Accordingly, the term "width" typically refers to the shorter dimension in the plane of the first side of the backing (featured side), which is the surface bearing the rail segments and posts. As used herein the term "thickness" usually refers to the smallest dimension of the fastener, which is the dimension perpendicular to the first side of the backing.

The term "alternating" as used herein refers to one row of rail segments being disposed between any two adjacent rows of posts (i.e., the rows of posts have only one row of rail segments between them) and one row of posts being disposed between any two adjacent rows of rail segments.

The term "perpendicular" as used herein to refer to the relationship between the backing and the rail segments and/or posts includes substantially perpendicular. "Substantially perpendicular" means that the planes defined by the backing and a row of rail segments or posts can deviate from perpendicular by up to <NUM> (in some embodiments, up to <NUM> or <NUM>) degrees.

The term "physiological parameter" refers to any measurement relating to a bodily function of a mammal. Examples include temperature, heart rate, ECG, blood pressure, blood flow, blood volume, respiration, skin condition, shivering, blood sugar, or combinations thereof.

The term "through-holes" refers to a technique in which protrusions on discrete components are inserted through holes in a substrate.

The term "slidable" refers to an ability to slide relative to another component in the longitudinal direction.

The term "tube" refers to a hollow elongated cylinder-type shape.

The term "electrically conductive" refers to an ability to conduct an electric current. Electrically conductive materials have an electrical conductivity of at least <NUM> Siemens per centimeter.

The term "electrically insulated" or "electrically insulative" refers to how strongly that material opposes the flow of electric current. Electrically insulated means having a surface resistivity of at least <NUM>^<NUM> Ohm/sq.

The term "electrically conductive layer" refers to a uniform layer of electrically conductive material or an uneven coating of electrically conductive material such that the entire coating is conductive from one end to the other end.

The term "mammalian subject" refers to any animal of the Mammalia, a large class of warm-blooded vertebrates having mammary glands in the female, a thoracic diaphragm, and a four-chambered heart. The class includes the whales, carnivores, rodents, bats, primates, humans, etc..

The term "electronic device" refers to a device depending on the principles of electronics and using the manipulation of electron flow for its operation. Electronic devices may be used in or facilitate monitoring one or more physiological parameters of a mammalian subject. Examples of electronic devices include heart rate monitors, wearable computers, insulin pumps, batteries, sensors, etc..

The term "frictionally resistive" refers to the cap normal force multiplied by the friction coefficient of the base polymers on themselves.

As used herein in connection with a measured quantity, the term "about" refers to that variation in the measured quantity as would be expected by the skilled artisan making the measurement and exercising a level of care commensurate with the objective of the measurement and the precision of the measuring equipment used. Herein, "up to" a number (e.g., up to <NUM>) includes the number (e.g., <NUM>).

All numerical ranges are inclusive of their endpoints and nonintegral values between the endpoints unless otherwise stated (e.g., <NUM> to <NUM> includes <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, etc.).

Claim 1:
A self-mating fastener (<NUM>; <NUM>; <NUM>; <NUM>; <NUM>; <NUM>; <NUM>; <NUM>; <NUM>; <NUM>; <NUM>; <NUM>; <NUM>; <NUM>; <NUM>; <NUM>), comprising:
a backing (<NUM>; <NUM>; <NUM>; <NUM>; <NUM>; <NUM>; <NUM>) having a first side (<NUM>; <NUM>); and
a rail element (<NUM>, <NUM>, <NUM>; <NUM>, <NUM>; <NUM>; <NUM>; <NUM>; <NUM>) protruding perpendicularly from the first side of the backing, the rail element extends in a longitudinal direction along the backing;
an electrically conductive contact element proximate to the rail element;
wherein the rail element has a base portion (<NUM>; <NUM>, <NUM>, <NUM>; <NUM>) attached to the first side of the backing and a cap portion (<NUM>; <NUM>, <NUM>, <NUM>; <NUM>) distal from the backing,
wherein the cap portion has a cap width (X4) that is greater than a width (X1) of the base portion,
wherein the cap portion overhangs the base portion on opposing sides,
wherein the rail element comprises a plurality of rail segments (<NUM>, <NUM>; <NUM>, <NUM>, <NUM>) arranged in a row (<NUM>);
a post element (<NUM>, <NUM>; <NUM>, <NUM>; <NUM>; <NUM>) extending perpendicularly from the first side of the backing and extending in a longitudinal direction along the backing and adjacent to the rail element,
wherein the post element comprises a plurality of posts that are (<NUM>; <NUM>, <NUM>) arranged in a row (<NUM>); and
wherein the self-mating fastener has at least three of the rows of rail segments alternating with at least three of the rows of posts.