Methods of Making Waterproof Curved Zippers
20220361633 · 2022-11-17
Assignee
Inventors
Cpc classification
A44B19/32
HUMAN NECESSITIES
A44B19/06
HUMAN NECESSITIES
International classification
Abstract
A waterproof zipper with at least one curve includes a first tape and a second tape, and interlocking elements attached to the first tape and the second tape, wherein the first tape and the second tape are curved, and wherein a curve of at least one of the tapes was caused by compaction of that tape. The zipper is coated on at least one side with a fluid impervious coating.
Claims
1-20. (canceled)
21. A method comprising: (A) providing a zipper with a left tape and a right tape connected to a rail of interlocking elements; (B) with the interlocking elements interlocked, putting TPU (thermoplastic polyurethane) between the interlocking elements; (C) compacting the left tape and the right tape and forming at least one curve in the zipper; and then (D) coating one or both sides of the zipper with fluid-impervious coating; and then (E) scoring the fluid-impervious coating along the rail.
22. The method of claim 21, wherein TPU is put between the interlocking elements in (B) after the compacting in (C).
23. The method of claim 21, wherein at least a curved portion of the left tape and a corresponding curved portion of the right tape are asymmetric about the interlocking elements.
24. The method of claim 21, wherein, after compacting in (C), the zipper has more than one curve.
25. The method of claim 21, wherein, in (A), the zipper is straight.
26. The method of claim 21, wherein, in (B), the TPU is blown and/or injected into the interlocking elements under pressure.
27. The method of claim 21, wherein, in (D), the coating is applied in the form of an adhesive strip.
28. A method comprising: (A) providing (a) a first zipper with a first left tape and a first right tape connected to a first rail of first interlocking elements, and (b) a second zipper with a second left tape and a second right tape connected to a second rail of second interlocking elements; (B) compacting the first left tape and the first right tape, and compacting the second left tape and the second right tape; and then (C) forming a third zipper from the left first tape and the right second tape; (D) with the interlocking elements of the third zipper interlocked, putting TPU (thermoplastic polyurethane) between the interlocking elements of the third zipper; (E) curving the third zipper to form at least one curve in the third zipper; and then (F) coating one or both sides of the third zipper with fluid-impervious coating; and then (G) scoring the fluid-impervious coating along the rail of the third zipper.
29. The method of claim 28 wherein the zipper is curved in (E) before putting TPU between the interlocking elements.
30. The method of claim 28, wherein, for the third zipper, at least a curved portion of the left first tape and a corresponding curved portion of the right second tape are asymmetric about the interlocking elements.
31. The method of claim 28, wherein the third zipper has more than one curve.
32. The method of claim 28, wherein, in (A), the first zipper is straight, and the second zipper is straight.
33. The method of claim 28, wherein, in (D), the TPU is blown and/or injected under pressure into the first interlocking elements and into the second interlocking elements.
34. The method of claim 28, wherein, in (F), the coating is applied in the form of an adhesive strip.
35. A method comprising: (A) providing (a) a first zipper with a first left tape and a first right tape connected to a first rail of first interlocking elements, and (b) a second zipper with a second left tape and a second right tape connected to a second rail of second interlocking elements; (B) with the first interlocking elements of the first zipper interlocked, putting TPU (thermoplastic polyurethane) between the first interlocking elements; and with the second interlocking elements of the second zipper interlocked, putting TPU between the second interlocking elements; (C) compacting the first left tape and the first right tape, and compacting the second left tape and the second right tape; (D) forming a third zipper from the left first tape and the right second tape; (E) curving the third zipper formed in (D) to form at least one curve in the third zipper; and then (F) coating one or both sides of the third zipper with fluid-impervious coating; and then (G) scoring the fluid-impervious coating along the rail of the third zipper.
36-41. (canceled)
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0135] Various other objects, features and attendant advantages of the present invention will become fully appreciated as the same becomes better understood when considered in conjunction with the accompanying drawings, in which like reference characters designate the same or similar parts throughout the several views, and wherein:
[0136]
[0137]
[0138]
[0139]
[0140]
DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EXEMPLARY EMBODIMENTS
[0141] Zippers according to exemplary embodiments hereof are described here.
[0142] The following detailed description is not intended to limit the current invention. Alternate embodiments and variations of the subject matter described herein will be apparent to those skilled in the art.
BACKGROUND
[0143] As shown in
[0144] The left and right side channels 102, 106 may combine below piece 110 within the body cavity of slider 100 (generally hidden from view and depicted with dashed lines in
[0145] As is also well known, the slider 100 may be moved from one end of the zipper to the other. As the slider is moved in one direction, the rows of teeth (the left row of teeth 14 and right row of teeth 18) may continue to be interlocked as they pass through slider 100 to form the length of the combined zipper chain 12. As slider 100 is moved in the other direction, it may contact the joined zipper chain 12 at a junction between the left row of teeth 14 and the right row of teeth 18 to force them apart, separate them from one another, and generally unlock the two rows of teeth 14, 18. This separation and unlocking may result in two separate and individual rows of teeth 14, 18. This allows zipper chain 12 to be combined to fasten the left and right sides together and separated to unfasten them. In this way, the zipper 10 may be used as a fastener for jackets, pockets, luggage, and other products.
[0146] The interlocking elements may be connected directly to the left and right tapes (e.g., in the case where they are metal teeth or the like), or they may be attached to a separate chain which is then attached to the left and right tapes.
DESCRIPTION
[0147] Curved zippers (i.e., zippers having at least one curved portion) may be formed, e.g., as described in PCT/IB2020/061005, titled “Curved Zipper,” published as WO/2021/100021 on May 27, 2021, the entire contents of which are fully incorporated herein by reference for all purposes.
[0148] In order to make zippers that curve according to exemplary embodiments hereof, the zipper tapes may be curved with or without the teeth elements attached to the tapes.
[0149] In some cases, e.g., as shown in
[0150] The self-edge 72 has a width Ws, and the rest of the tape has a width Wr, where Wt=Ws+Wr is the width of the tape. Those of skill in the art will know and understand, upon reading this description, how to select the ratio of Ws to Wr (or of Ws to Wt) to achieve a desired curvature for the zipper. For example, the width Wr will affect the amount of compaction of that portion of the tape.
[0151] The widths Ws and Wr and Wt (of the tape) could be the same or different on the left and right tapes. In some cases, Wt is the same on both the left and right tapes, but the widths Ws and Wr differ. In other cases, Wt is different on the left and right tapes. As shown in the example in
[0152] The tape 70 may be compacted using a heated compactor. Since the self-edge has a tighter weave than the rest of the tape, when compacted, the self-edge 72 will compact less than the rest of tape 74. Thus, after compaction, the rest of the tape 74 will open up more than the self-edge 72. This will cause the tape 70 to curve, e.g., as shown in
[0153] As shown, e.g., in
[0154] The curved portion of tape 70-L shown in
[0155] As used herein, the term “radius of curvature” for a curve at a point may be the radius of a circular arc that best approximates the curve at that point. Thus, for a curved portion of a tape, the radius of curvature at a point on that curved portion may be the radius of the circular arc which best approximates the curve at that point on the tape. For two tapes (a first tape and a second tape (e.g., a left tape and a right tape)), a first point or location of the first tape corresponds to a second point or location of the second tape if an interlocking element (e.g., a tooth) at the first point or location on the first tape connects to a corresponding interlocking element (e.g., a tooth) at the second point or location on the second tape. As used herein, a first portion of a first tape corresponds to a second portion of a second tape if the interlocking elements (e.g., teeth) in the first portion of the first tape connect to corresponding teeth in the second portion of the second tape.
[0156] The left and right tapes 70-L and 70-R may have different degrees of compaction. In general, the left tape 70-L may have CL percent compaction, while the right tape 70-R may have CR percent compaction, where, in some cases, CL CR. For example, without limitation, the left tape 70-L may have 5 percent compaction while the right tape 70-R may have 15 percent compaction.
[0157] The two curved tapes 70-L, 70-R, joined with/by their interlocking elements (e.g., teeth), as shown in
[0158]
[0159] As should be appreciated, for curved portions of a curved zipper, corresponding curved portions of the tapes (left and right tapes) are asymmetric about the interlocking elements, whereas for straight portions of a zipper, the tapes are symmetric about the interlocking elements.
[0160] If the tapes 70-L, 70-R are compacted with a drum, the tapes may be processed on opposite sides of the drum before being joined with the teeth.
[0161] The zipper may be formed with pre-compacted or un-compacted tapes, and then the fully formed zipper may be compacted.
[0162] An exemplary approach to compacting the zippers is shown in
[0163] As shown in
[0164] One or both of the drums 42, 44 may be grooved and/or coated, at least in the regions that will come into contact with the tapes.
[0165] The compactor 38 may include a suitable guide mechanism 46 to position the zippers correctly and accurately 36 as the pass between the drums 42, 44.
[0166] In order to achieve compaction of the zippers 36, one or both of the drums may be heated. Those of skill in the art will understand, upon reading this description, that the amount of compaction of the tape by the compactor 38 will depend on the type and/or cut of material used for the tape, and the temperature, speed, and pressure of the compactor 38. The compressed zipper 48 will be able to stretch the amount compacted.
[0167] An exemplary approach to providing stretch and recovery is shown in
[0168] In order to allow zippers to stretch and recover, the tapes may be compacted to remove their shrinkage. Then a fusible (e.g., a 2-way fusible substrate) may be applied to the back of the tapes to provide memory to the tapes.
[0169] For example, as shown in
[0170] The speed, temperature, and pressure of the heating press 58 depend on the type of fabric used for the tapes and on the type of fusible substrate 56 being used.
[0171] The speed, temperature, and pressure of the heating press 58 need not be the same as those of the compactor 38, as the compactor 38 is used to compact the tape fabric, whereas the heating press 58 is used to fuse the fusible substrate 56 to the compacted tape fabric.
[0172] As shown in
[0173] The fusible substrate is preferably a 2-way stretchable fusible.
[0174] As an alternative, before the zipper is assembled, the tapes may be compacted (to remove shrinkage) and then fused with a fusible to provide memory to the tapes (so that they may recover after being stretched). Then the teeth may be applied to the compacted tapes that have already been fused with a fusible substrate. In this way, the zipper will be able to stretch the amount compacted and recover an amount depending on the fusible used.
[0175] An exemplary process of making a waterproof curved zipper is described with reference to the flowchart in
[0176] Start with a zipper 600 (at 502), where the zipper has a left tape 650-L and right tape 650-R connected to the rail or chain of interlocking elements 652. The rail or interlocking elements 652 is made up of left interlocking elements 652-L connected to the left tape 650-L and right interlocking elements 652-R connected to the right tape 650-R. The left interlocking elements 652-L and right interlocking elements 652-R, when interlocked, form the combined zipper chain 652. The interlocking elements 652 may be teeth or the like. To begin (at 502), the zipper 600 is preferably straight.
[0177] With the interlocking elements 652-L, 652-R interlocked (i.e., with the zipper closed), TPU or the like is put between the interlocking elements (at 504) and shown in
[0178] The tapes are then compacted (at 506), and then the zipper 602 with the TPU in the teeth is then curved (at 508), e.g., a described above. As noted, the curved zipper may have more than one curved portion or section.
[0179] The curved zipper is may then be coated (at 510) across one or both sides with a fluid-impervious coating (e.g., formed with TPU film or the like). The coating (TPU film or the like) may be applied in the form of an adhesive strip.
[0180] The fluid-impervious coating(s) 662 (and 664, if present) are cut or scored (at 510) along the rail 652 (preferably along the center of the rail 652), as shown in
[0181] In some embodiments the TPU may be put between the teeth (interlocking elements) after the zipper is curved.
[0182] In other exemplary embodiments hereof, the tapes of distinct zippers (e.g., having distinct compaction properties) may be combined to form a combined zipper. With reference to the flowchart in
[0183] The first zipper 700 has a left tape 750-L and right tape 750-R connected to the rail or chain of interlocking elements 752. The rail or interlocking elements 752 is made up of left interlocking elements 752-L connected to the left tape 750-L and right interlocking elements 752-R connected to the right tape 750-R. The left interlocking elements 752-L and right interlocking elements 752-R, when interlocked, form the combined zipper chain 752.
[0184] The second zipper 702 has a left tape 750-L′ and right tape 750-R′ connected to the rail or chain of interlocking elements 752′. The rail or interlocking elements 752′ is made up of left interlocking elements 752-L′ connected to the left tape 750-L′ and right interlocking elements 752-R′ connected to the right tape 750-R′. The left interlocking elements 752-L′ and right interlocking elements 752-R′, when interlocked, form the combined zipper chain 752′.
[0185] To begin, the two zippers 700, 702 are preferably straight.
[0186] With the two zippers, each closed, TPU or the like is put between the interlocking elements of each zipper (at 514) and depicted in
[0187] The two zippers 700, 702 are then compacted, e.g., with different degrees of compaction (at 516). For example, the first zipper 700 may be compacted X percent, while the second zipper 702 may be compacted Y percent, with X≠Y. For example, X may be in the range 5-10, with Y being in the range 10-20. Exemplary compaction rates are 5% and 15%.
[0188] Next, form a combined hybrid zipper 704 (at 518) with one tape from one zipper and the other tape from the other zipper (e.g., as shown in
[0189] One or both sides (i.e., front/outside and/or back/inside) of the combined hybrid zipper 704 are then coated (at 522) with a fluid impervious coating/film (e.g., coating 762 on the bottom (back/inside) of the zipper, shown in
[0190] In other exemplary embodiments hereof, the tapes of distinct zippers (e.g., having distinct compaction properties and/or different widths) may be combined to form a combined zipper as described with reference to the flowchart in
[0191] Thus, the process of
[0192] Next, a combined hybrid zipper is formed (at 518′) with one tape from one zipper and the other tape from the other zipper (zipper 804,
[0193] TPU is put between the teeth of the combined hybrid zipper (at 519) (
[0194] The combined hybrid zipper is curved (at 520).
[0195] One or both sides (i.e., front/outside and/or back/inside) of the combined hybrid zipper are then coated (at 522′) with a fluid impervious coating/film (e.g., on the bottom (back/inside) of the zipper, or coatings and on both sides of the zipper) (
Connecting Zippers to Items (Products)
[0196] The zippers described herein are preferably waterproof. When connected to an item (e.g., garment, luggage, etc.), it is desirable for the connection also to be waterproof.
[0197] In some cases, a zipper may be stitched to an item by stitching along the tapes. The stitching creates holes in the tapes that may cause some leakage. The leakage may be minimal and may be tolerable for a particular application (e.g., a suitcase). Alternatively, the stitching may use a thread that swells when wet, thereby blocking the holes when the item gets wet.
[0198] Instead or in addition, a sealing tape may be applied to the item after the zipper is attached, covering the holes caused by the stitching.
[0199] In some cases, the tapes may be attached by welding or glue or the like, with or without stitching.
[0200] In addition to leakage caused by stitching, as described above, there may be some leakage at the slider. Again, such leakage may be minimal and tolerable.
[0201] Additional structure may be added to at least some of the items to further cover the zipper to maintain the waterproofing of the items.
EXAMPLES
[0202] 1.1 A waterproof zipper is provided having one or more curves.
1.2 One or more waterproof zippers, each having one or more curves, are used with a product.
1.3 One or more waterproof zippers, each having one or more curves, are used with a product selected from: a garment, footwear, an item of luggage, an item of sports equipment, boat covers, bags, pencil cases, backpacks, computer/laptop cases, luggage, zip-up portfolio case, zip-up storage bins for toys, sleeping bags, tents, children make up/toiletry bags, lunch bags, hats with zipper pockets, toys, toy clothing, a handbag, and others.
[0203] Thus are described various waterproof zippers, items using the waterproof zippers, and methods of making the waterproof zippers and the items.
CONCLUSION
[0204] As used herein, including in the claims, the phrase “at least some” means “one or more” and includes the case of only one. Thus, e.g., the phrase “at least some ABCs” means “one or more ABCs” and includes the case of only one ABC.
[0205] As used in this description, the term “portion” means some or all. So, for example, “A portion of X” may include some of “X” or all of “X”. In the context of a conversation, the term “portion” means some or all of the conversation.
[0206] As used herein, including in the claims, the phrase “using” means “using at least” and is not exclusive. Thus, e.g., the phrase “using X” means “using at least X.” Unless specifically stated by use of the word “only”, the phrase “using X” does not mean “using only X.”
[0207] In general, as used herein, including in the claims, unless the word “only” is specifically used in a phrase, it should not be read into that phrase.
[0208] As used herein, including in the claims, the phrase “distinct” means “at least partially distinct.” Unless specifically stated, distinct does not mean fully distinct. Thus, e.g., the phrase, “X is distinct from Y” means that “X is at least partially distinct from Y,” and does not mean that “X is fully distinct from Y.” Thus, as used herein, including in the claims, the phrase “X is distinct from Y” means that X differs from Y in at least some way.
[0209] It should be appreciated that the words “first,” “second,” and “third,” in the description and claims are used to distinguish or identify and not to show a serial or numerical limitation. Similarly, the use of letter or numerical labels (such as “(a),” “(b),” “(c),” and so on, or “(A),” “(B),” “(C),” and so on, or “(i),” “(ii),” and so on, and the like) are used to help distinguish and/or identify, and are not intended to be otherwise limiting or to impose or imply any serial or numerical limitations or orderings.
[0210] While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiments, it is to be understood that the invention is not to be limited to the disclosed embodiments, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.