COPYRIGHT STATEMENT

A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever.

FIELD

This invention relates generally to zippers and, more particularly, in some aspects, to curved zippers and to zippers that stretch and recover.

BACKGROUND

Zippers are ubiquitous and have long been used to fasten or otherwise secure items such as jackets, luggage, pockets, and other types of products. A typical zipper may include a slider configured with two face-to-face rows of elements or teeth or interlocking spirals. The rows of elements are typically connected to a tape or the like, and, as the slider is moved along the tape in one direction, the two rows of teeth may pass through the slider, and the teeth may be interlocked, resulting in a combined zipper chain. As the slider is moved along the tape in the opposite direction, the rows of teeth separate. In this way, as is well known, an item configured with the zipper may be fastened or unfastened.

Conventionally, the tapes are made of a fabric or substrate such as cotton or polyester or nylon. The interlocking elements (e.g., teeth or a coil) may be made up of many things, including brass, steel, stainless steel, nylon, or poly.

The inventor has realized that conventional zippers have various problems, including:(1) The tapes may shrink, making an attached item (e.g., a garment) look unsightly. Sometimes the tapes may not shrink in the same amount as the garment fabric to which it is attached, making the garment look unsightly.(2) Zippers do not stretch.(3) Zippers do not stretch and recover.(4) Zippers generally cannot curve, so they are attached to items (e.g., garments or bags or the like) “standing up”—in a straight line.

Curved zippers are known in principle from the art.

Some approaches use cuts and notches in the carrier tapes in the region of the desired bend. Examples of these are shown inFIGS. 1A-1F(seeFIG. 2aof US20130205548A1 inFIG. 1A;FIG. 4of WO2006000086A2 inFIG. 1B;FIG. 6of WO2017117285A1 inFIG. 1C;FIGS. 1 and 2of DE7122407 inFIGS. 1D-1E; andFIG. 1of CN201782133U inFIG. 1F).

The “cuts and notches” approach has various drawbacks, including that the cuts and notches create weak locations in the carrier tapes.

Another known approach to curved zippers, shown in U.S. Pat. No. 8,011,070, attaches “stretchable members” to the zipper tapes in various locations “as a reinforcement member for the fastener tape to maintain its curved shape”. U.S. Pat. No. 8,011,070 col. 7, lines 57-58 (see alsoFIG. 2of U.S. Pat. No. 8,011,070 reproduced in part inFIG. 1Ghereof). As described in U.S. Pat. No. 8,011,070, the so-called stretchable member has to be held (sewn) in place in its deformed (curved) state; otherwise it will be restored to its original state. In another configuration in U.S. Pat. No. 8,011,070, “the stretchable member . . . may be formed by coating the tape surface . . . of the fastener tape . . . with a rubber made belt material . . . continuously in the length direction of the fastener tape . . . in a belt-like formation . . . . The belt material . . . is applied to the fastener tape . . . by coating in a state in which the rubber is heated to be softened, so that the rubber invades in between fibers of the fastener tape . . . and fixed integrally with the fastener tape . . . . Thus, no adhesive layer is needed to fix the belt material . . . to the fastener tape.” U.S. Pat. No. 8,011,070, col. 8, lines 55-64.

A method of producing a curved zipper is known from U.S. Pat. No. 5,065,491A, in which a carrier tape of solvent-swelling fibers is produced so that the fibers swell when a solvent is applied to the carrier tape, and the tape (and zipper) is shaped into the desired curved configuration. The shape is not retained permanently. The method is not suitable for production by machine, and it is expensive.

Accordingly, it is desirable and an object hereof to provide a curved zipper that maintains its curve, even when not connected to a garment or other device.

It is also desirable and an object hereof to provide a curved zipper that does not have weak attachment points and thus maintains its strength and integrity along its length.

It is further desirable and an object hereof to provide a zipper that does not have excessive shrinkage.

It is further desirable and an object hereof to provide a zipper with uniform shrinkage.

It is further desirable and an object hereof to provide a zipper with stretch properties.

It is further desirable and an object hereof to provide a zipper with stretch and recovery properties.

SUMMARY

The present invention is specified in the claims and the below description. The following summary is exemplary and not limiting. Presently preferred embodiments are particularly specified in the dependent claims and the description of various embodiments.

Zippers That Deal with too Much Shrinkage

One general aspect includes a zipper with two tapes, where at least one of the two tapes is formed from a compacted fabric. The zipper also includes multiple interlocking elements (e.g., teeth) connected to each of the two tapes, where interlocking elements from each tape of the two tapes may join with interlocking elements of the other of the two tapes.

Implementations may include one or more of the following features, alone or in combination(s):the zipper where the fabric is selected from cotton or polyester or nylon; and/orthe zipper where the tapes were compacted before being connected to the interlocking elements; and/orthe zipper where the interlocking elements may include teeth or a coil; and/orthe zipper where the interlocking elements are formed from brass or steel or stainless steel or nylon; and/orthe zipper where the two tapes have different degrees of compaction.

Zippers That Deal with too Little Shrinkage

Another general aspect includes a garment may include a garment fabric and a zipper attached to one or more portions of the garment fabric.

Implementations may include one or more of the following features, alone or in combination(s):the garment where the garment fabric is preshrunk by compaction; and/orthe garment where the zipper may include two zipper tapes, and where the zipper tapes have a first shrinkage and where the garment fabric has a second shrinkage larger than the first shrinkage; and/orthe garment where the zipper may include two zipper tapes, and where the zipper tapes have a first and second shrinkage and where the garment fabric has a third shrinkage larger than the first and second shrinkages; and/orthe garment where the garment fabric was preshrunk such that the shrinkage of the preshrunk garment fabric is substantially equal to the shrinkage of the zipper tapes.

Another general aspect includes a method of making a garment. The method of making also includes providing a zipper having two zipper tapes, where the zipper tapes have a first shrinkage, and providing a garment fabric where the garment fabric has a second shrinkage larger than the first shrinkage. The method also includes compacting the garment fabric to produce a compacted garment fabric, where the compacted garment fabric has a third shrinkage, where the third shrinkage is substantially equal to the first shrinkage. The method also includes connecting the zipper tapes to the compacted garment fabric.

Implementations may include washing the garment.

Zippers That Stretch

Another general aspect includes a zipper having two tapes, each formed from a compacted fabric. The zipper also includes multiple interlocking elements (e.g., teeth) attached to the two tapes after the fabric was compacted, where interlocking elements from each tape may join with interlocking elements of the other tape.

Implementations may include one or more of the following features, alone or in combination(s):where the compacted fabric was compacted to remove all or substantially all shrinkage of the fabric; and/orwhere the tapes have different degrees of compaction.

Another general aspect includes a method of making a zipper, including compacting two tapes to form two compacted tapes; and then attaching interlocking elements to the two tapes.

Implementations may include one or more of the following features, alone or in combination(s):where the two tapes are compacted to remove substantially all of their shrinkage; and/orwhere the tapes have different degrees of compaction.

Another general aspect includes a method of making a zipper, including attaching interlocking elements to two tapes; and then compacting the two tapes.

Implementations may include one or more of the following features, alone or in combination(s):the method where compaction of the two tapes uses a compactor; and/orthe method where the compactor includes at least one drum; and/orthe method where the drum has a notch or groove to allow the zipper's interlocking elements to pass without pressure from the drum while the tapes on either side of the interlocking elements are being compacted; and/orwhere the tapes have different degrees of compaction; and/orthe method where the drum is heated.

Another general aspect includes a drum for a compactor, where the drum has a notch or groove to allow a zipper's interlocking elements to pass without pressure from the drum while tapes on either side of the zipper's interlocking elements are being compacted by the drum.

Zippers That Stretch and Recover

Another general aspect includes a zipper including two tapes, each formed from a compacted fabric, where at least one of the two tapes has a fusible substrate fused with the compacted fabric. The zipper also includes multiple interlocking elements connected to each of the two tapes, where interlocking elements from each tape may join with interlocking elements of the other tape.

Implementations may include one or more of the following features, alone or in combination(s):the zipper where both of the tapes include the fusible substrate fused with the compacted fabric; and/orthe zipper where at least one of the two tapes may include the fusible substrate fused with the compacted fabric along substantially a length of the tapes; and/orthe zipper where interlocking elements were attached to the two tapes after the fabric was compacted; and/orthe zipper where interlocking elements were attached to the two tapes after the fusible substrate was fused with the compacted fabric; and/orwhere the tapes have different degrees of compaction.

Another general aspect includes a method of making a zipper. The method includes compacting a tape to form a compacted tape and fusing a fusible substrate to the compacted tape. The method also includes attaching interlocking elements to the compacted tape.

Implementations may include one or more of the following features, alone or in combination(s):the method may include compacting a second tape to form a second compacted tape; fusing the fusible substrate to the second compacted tape; and attaching the interlocking elements to the second compacted tape; and/orthe method where the tape is compacted using a heated drum; and/orwhere the tapes have different degrees of compaction.

Another general aspect includes a method of making a zipper, including attaching a first tape to a first side of a zipper chain and attaching a second tape to a second side of the zipper chain; and then compacting the first tape and the second tape; and then fusing a fusible substrate with the first tape.

Implementations may include fusing the fusible substrate with the second tape.

Zippers That Curve

Another general aspect includes a zipper having a first tape and a second tape and interlocking elements attached to the first tape and the second tape, where the first tape and the second tape are curved, and wherein a curve of the first tape was caused by compaction of the first tape.

Implementations may include one or more of the following features, alone or in combination(s):the zipper where a curve of the second tape was caused by compaction of the second tape; and/orthe zipper where the second tape is woven with a second edge portion having a tighter weave than the rest of the second tape; and/orthe zipper where the first tape was compacted using a compactor; and/orthe zipper where the first tape is woven with a first edge portion having a tighter weave than the rest of the first tape; and/orthe zipper where interlocking elements were attached to the first tape after the first tape was curved; and/orthe zipper where interlocking elements were attached to the second tape after the second tape was curved; and/orthe zipper where interlocking elements were attached to the first tape before the first tape was curved; and/orthe zipper where interlocking elements were attached to the second tape before the second tape was curved; and/orthe zipper where at least a portion of the first tape has stretch; and/orthe zipper where at least a portion of the first tape has stretch and recovery properties; and/orthe zipper where at least a portion of the first tape is fused with a fusible substrate; and/orthe zipper where the first and second tapes have different degrees of curvature;the zipper where less than the entire zipper is curved; and/orthe zipper where the zipper has more than one curve.

Another general aspect includes a method of making a zipper, including providing a first tape, the first tape woven with a first edge portion having a tighter weave than the rest of the first tape. The making also includes compacting a first tape to form a curved first tape. The making also includes attaching interlocking elements to the curved first tape.

Implementations may include one or more of the following features, alone or in combination(s):the method may include attaching a curved second tape to the interlocking elements; and/orthe method where the curved second tape was formed by compaction; and/orthe method where the first and second tapes have different degrees of curvature; and/orthe method may include after the compacting, fusing a fusible substrate to the first tape.

Yet another general aspect includes a product including a zipper assembly according to any of the previous embodiments. The product may be, e.g., a garment, clothing, footwear (shoes, boots, etc.), an item of luggage, or a sports item. Non-limiting examples of products include, without limitation, bags, pencil cases, backpacks, computer/laptop cases, luggage, zip-up portfolio case, zip-up storage bins for toys, sleeping bags, tents, boat covers, children make up/toiletry bags, lunch bags, hats with zipper pockets, toys, toy clothing, etc.

Below is an exemplary list of zipper embodiments, method/process embodiments, and garment embodiments. The zipper embodiments will be indicated with a letter “Z”. Whenever such embodiments are referred to, this will be done by referring to “Z” embodiments. The garment embodiments will be indicated with a letter “G”. Whenever such embodiments are referred to, this will be done by referring to “G” embodiments. The method embodiments will be indicated with a letter “M”. Whenever such embodiments are referred to, this will be done by referring to “M” embodiments. Drum embodiments will be indicated with a letter “DR”. Whenever such embodiments are referred to, this will be done by referring to “DR” embodiments.Z1. A zipper comprising:two tapes; andmultiple interlocking elements connected to each of the two tapes,wherein interlocking elements from each tape of the two tapes may join with interlocking elements of the other of the two tapes, andwherein at least one of the two tapes is formed from a compacted fabric.Z2. The zipper of embodiment Z1, wherein the fabric is selected from cotton or polyester or nylon.Z3. The zipper of embodiment(s) Z1 or Z2, wherein the tapes were compacted after being connected to the interlocking elements.Z3′. The zipper of embodiment(s) Z1 or Z2, wherein the tapes were compacted prior to being connected to the interlocking elements.Z4. The zipper of embodiment(s) Z1-Z3′, wherein the tapes have different degrees of compaction.Z5. The zipper of any of embodiment(s) Z1-Z4, wherein the interlocking elements comprise teeth or a coil.Z6. The zipper of any of embodiment(s) Z1-Z5, wherein the interlocking elements are formed from brass or steel or stainless steel or nylon.G7. A garment comprising a garment fabric and a zipper attached to one or more portions of the garment fabric, wherein at least some of the garment fabric is preshrunk before attachment to the zipper.G8. The garment of embodiment(s) G7, wherein the garment fabric is preshrunk by compaction.G9. The garment of embodiment(s) G7 or G8, wherein the zipper comprises two zipper tapes, and wherein the zipper tapes have a first shrinkage and wherein the garment fabric has a second shrinkage larger than said first shrinkage.G10. The garment of any of embodiment(s) G76-G9, wherein the garment fabric was preshrunk such that the shrinkage of the preshrunk garment fabric is substantially equal to the shrinkage of the zipper tapes.M11. A method of making a garment, the method comprising:providing a zipper having two zipper tapes, wherein the zipper tapes have a first shrinkage;providing a garment fabric wherein the garment fabric has a second shrinkage larger than said first shrinkage;compacting the garment fabric to produce a compacted garment fabric, wherein the compacted garment fabric has a third shrinkage, wherein said third shrinkage is substantially equal to the first shrinkage; andconnecting the zipper tapes to the compacted garment fabric.M12. The method of embodiment(s) M11 further comprising washing the garment.Z13. A zipper comprising:two tapes, each formed from a compacted fabric; andmultiple interlocking elements connected to each of the two tapes,wherein interlocking elements from each tape may join with interlocking elements of the other tape, andwherein interlocking elements were attached to the two tapes after the fabric was compacted.Z13′. A zipper comprising:two tapes, each formed from a compacted fabric; andmultiple interlocking elements connected to each of the two tapes,wherein interlocking elements from each tape may join with interlocking elements of the other tape, andwherein interlocking elements were attached to the two tapes before the fabric was compacted.Z14. A zipper according to embodiment(s) Z13 or Z13′, wherein the compacted fabric was compacted to remove all or substantially all shrinkage of the fabric.M15. A method of making a zipper, the method comprising:compacting two tapes to form two compacted tapes; andattaching interlocking elements to the two tapes.M16. A method of making a zipper, the method comprising:attaching interlocking elements to two tapes; and thencompacting the two tapes.M17. The method of embodiment(s) M15 or M16, wherein the two tapes are compacted to remove substantially all of their shrinkage.M18. The method of any of embodiment(s) M15-M17, wherein compaction of the two tapes uses a compactor.M19. The method of any of embodiment(s) M15-M18, wherein the two tapes have different degrees of compaction.M20. The method of embodiment(s) M19, wherein the compactor includes at least one drum.M21. The method of embodiment(s) M20, wherein the at least one drum has a notch or groove to allow a zipper's interlocking elements to pass without pressure from the at least one drum while the tapes on either side of the interlocking elements are being compacted by the at least one drum.M22. The method of embodiment(s) M20-M21, wherein the at least one drum is heated.DR23. A drum for a compactor, the at least one drum comprising a notch or groove to allow a zipper's interlocking elements to pass without pressure from the at least one drum while tapes on either side of the zipper's interlocking elements and attached to the zipper are being compacted by the at least one drum.Z24. A zipper comprising:two tapes, each formed from a compacted fabric, wherein at least one of the two tapes comprises a fusible substrate fused with the compacted fabric; andmultiple interlocking elements connected to each of the two tapes, wherein interlocking elements from each tape may join with interlocking elements of the other tape.Z25. The zipper of embodiment(s) Z24, wherein the two tapes have different degrees of compaction.Z26. The zipper of embodiment(s) Z24-Z25, wherein both of the two tapes comprise said fusible substrate fused with the compacted fabric.Z27. The zipper of embodiment(s) Z24-Z26, wherein at least one of the two tapes comprises said fusible substrate fused with the compacted fabric along substantially a length of the tapes.Z28. The zipper of any of embodiment(s) Z24-Z27, wherein the interlocking elements were attached to the two tapes after the fabric was compacted.Z29. The zipper of any of embodiment(s) Z24-Z28, wherein the interlocking elements were attached to the two tapes after the fusible substrate was fused with the compacted fabric.M30. A method of making a zipper, the method comprising:compacting a tape to form a compacted tape;fusing a fusible substrate to the compacted tape; andattaching interlocking elements to the compacted tape.M31. The method of embodiment(s) M30, further comprising:compacting a second tape to form a second compacted tape;fusing said fusible substrate to the second compacted tape; andattaching interlocking elements to the second compacted tape.M32. The method of embodiment(s) M30 or M31, wherein the tape is compacted using a heated drum.M33. A method of making a zipper, the method comprising:attaching interlocking elements to a first tape and to a second tape; and thencompacting the first tape and the second tape; and thenfusing a fusible substrate with the first tape.M34. The method of embodiment(s) M33 further comprising:fusing said fusible substrate with the second tape.Z35. A zipper comprising:a first tape and a second tape; andinterlocking elements attached to the first tape and the second tape,wherein the first tape and the second tape are curved, andwherein a curve of the first tape was caused by compaction of the first tape.Z36. The zipper of embodiment(s) Z35, wherein the tapes have different degrees of compaction.Z37. The zipper of embodiment(s) Z35-Z36, wherein a curve of the second tape was caused by compaction of the second tape.Z38. The zipper of embodiment(s) Z35-Z37, wherein the first tape was compacted using a heated press.Z39. The zipper of any of embodiment(s) Z35-Z38, wherein the first tape is woven with a first edge portion having a tighter weave than the rest of the first tape.Z40. The zipper of any of embodiment(s) Z35-Z39, wherein the second tape is woven with a second edge portion having a tighter weave than the rest of the second tape.Z41. The zipper of any of embodiment(s) Z35-Z40, wherein the interlocking elements were attached to the first tape before the first tape was curved.Z41′. The zipper of any of embodiment(s) Z35-Z40, wherein the interlocking elements were attached to the first tape after the first tape was curved.Z42. The zipper of any of embodiment(s) Z35-Z41′, wherein the interlocking elements were attached to the second tape before the second tape was curved.Z42′. The zipper of any of embodiment(s) Z35-Z41′, wherein the interlocking elements were attached to the second tape after the second tape was curved.Z43. The zipper of any of embodiment(s) Z35-Z42′, wherein at least a portion of the first tape has stretch.Z44. The zipper of any of embodiment(s) Z35-Z43, wherein at least a portion of the first tape has stretch and recovery properties.Z45. The zipper of any of embodiment(s) Z35-Z44, wherein at least a portion of the first tape is fused with a fusible substrate.Z46. The zipper of any of embodiment(s) Z35-Z45, wherein less than the entire zipper is curved.Z47. The zipper of any of embodiment(s) Z35-Z46, wherein the zipper has more than one curve.Z48. The zipper of any of embodiment(s) Z35-Z47, wherein the first tape has a different degree of curvature than the second tape.M49. A method of making a zipper, the method comprising:providing a first tape, said first tape woven with a first edge portion having a tighter weave than the rest of the first tape;compacting a first tape to form a curved first tape; andattaching interlocking elements to the curved first tape.M49′. A method of making a zipper, the method comprising:providing a first tape, said first tape woven with a first edge portion having a tighter weave than the rest of the first tape;attaching interlocking elements to the curved first tape; andcompacting a first tape to form a curved first tape.M50. The method of embodiment(s) M49-M49′, further comprising: attaching a curved second tape to the interlocking elements.M51. The method of embodiment(s) M49-M50, wherein the curved second tape was formed by compaction.M52. The method of any of embodiment(s) M49-M51, further comprising after said compacting, fusing a fusible substrate to the first tape.M53. The method of any of embodiment(s) M49-M52, wherein the first tape has a different degree of curvature than the second tape.

Below are product embodiments indicated with the letter “P”.P54. A product comprising a zipper according to any of the previous zipper embodiments.P55. The product of embodiment(s) P54, wherein the product is 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.

