Zip Fastener and Slider

FIELD OF TEE INVENTION

The present invention relates to zip fasteners (abbreviated to “zips”) and in particular, although not solely for the use in garments, clothing, bags, footwear, safety wear, and sports equipment (e.g. tents, racquet covers and wetsuits).

BACKGROUND OF THE INVENTION

Today, zips come in all shapes, sizes and materials for the numerous applications. They are sewn on the fabric of for example, different types of garment, bags, luggage and footwear. Most zips used in the garments industry or even bags, luggage and footwear utilise two zipper tracks presenting a series of tooth like elements which are able to move in and out of engagement with each other by the use of a slider. Such zips can be made of polyester zipper teeth, moulded zipper teeth or metal zipper teeth. The polyester zipper teeth and the moulded zipper teeth are usually injection moulded about a tape, whereas the metal zipper teeth are stamped out of metals strips like brass, aluminium, bronze or even nickel silver alloy. All these zips have different fashion appeal and varying strength and flexibility. Because the teeth interlock in the longitudinal direction of the zip, such zips cannot stretch to any useful extent longitudinally and retain closure. Stretching along the length of the zip would allow the teeth to separate. But this lack of stretchability is a disadvantage where zips are used in clothing, especially fashion clothing made of resilient or stretchable material.

Definitions

The following definitions relate to conventional toothed (chain) type zip fasteners but assist in explaining the component parts many of which have counterparts in the fastener of this invention.

Chain

The continuous piece that is formed when both halves of a zipper are meshed together.

Chain Size

Refers to the specific gauge of the chain, i.e., size of the teeth.

Teeth

The individual elements that make up the chain.

Slider

The device that moves up and down the chain to open or close the zipper.

Pull Tab

The part of the slider that you hold to move the slider up or down.

Material

Refers to the type of chain that is used in the construction of the zipper, such as, metal chain, moulded plastic chain or coil (nylon) chain.

Tape

The fabric part of the zipper.

Tape Width

Refers to the width of the fabric on one side only, of the zipper chain.

Tape Ends

The fabric part of the zipper that extends beyond the teeth, at the top and/or bottom of the chain.

Style

Refers to the manner in which the zipper is assembled for a particular application.

Top Stop

Two devices affixed to the top of a zipper, to prevent the slider from coming off the chain.

Bottom Stop

A device affixed to the bottom of a zipper, to prevent further movement of the half of the zipper from separating.

Bridge Stop

A device similar to a bottom stop, used at the top of a zipper to prevent each half of the zipper from separating.

A device used on a separating (jacket type) zipper whose function is to allow the joining of the two zipper halves.

Pin Box

A device used on a separating (jacket type) zipper whose function is to correctly align the pin, to begin the joining of the zipper halves.

Heat Seal Patch

The cotton and nylon laminated material fused to the bottom end of a separating zipper, used to reinforce the type.

Heat-Sealable Zippers (Weldable Laminated Zippers)

Any zipper that has a strip of plastic fused to each half of the zipper tape to allow a manufacturer to electronically “weld” the zipper onto the garment or item that is being manufactured, without the need of sewing or stitching.

Continuous Chain

Any material or size of zipper chain that is continuously spooled without sliders or any other components. Typically used by fabricators on a cut-as-need basis.

Cut-to-Length Zippers

(Finished Zippers.) Any zipper that is finished to a specific length, with all necessary components attached.

Types of Zips

Zip fasteners come in a variety of styles with one end closed, both ends closed, and both ends open. For example a trouser type zip has one end closed, and the slider retained on the zip by end stops. A bag type zip will typically have both ends of the zip closed and will typically have two sliders retained between the closed ends, so that as the sliders move towards the respective closed ends, the central portion of the zip fastener will open.

Jacket type zips on the other hand have both ends of the zip fastener open so that the slider will be retained on one side of the zip fastener when the jacket is open. Such an open ended zip fastener typically has a pin at the end of one side and a pin box on the other side of the zip fastener enabling the two sides to be connected together so that the slider can be used to merge the two sides of the zip fastener.

A number of other configurations have been used with conventional zip fasteners, and the zip fastener of this invention can be configured in all these different ways, whether or not they have all been illustrated in the attached drawings.

REFERENCES

All references, including any patents or patent applications cited in this specification are hereby incorporated by reference. No admission is made that any reference constitutes prior art. The discussion of the references states what their authors assert, and the applicants reserve the right to challenge the accuracy and pertinency of the cited documents. It will be clearly understood that, although a number of prior art publications are referred to herein; this reference does not constitute an admission that any of these documents form part of the common general knowledge in the art, in New Zealand or in any other country.

It is acknowledged that the term ‘comprise’ may, under varying jurisdictions, be attributed with either an exclusive or an inclusive meaning. For the purpose of this specification, and unless otherwise noted, the term ‘comprise’ shall have an inclusive meaning—i.e. that it will be taken to mean an inclusion of not only the listed components it directly references, but also other non-specified components or elements. This rationale will also be used when the term ‘comprised’ or ‘comprising’ is used in relation to one or more steps in a method or process.

SUMMARY OF PRIOR ART

The packaging industry has used “ziplock” fasteners in the closure of plastic bags for many years. They make use of a pair of mutually cooperative male and female extruded closure tracks positioned inside the bag and facing one another. Whilst such closures have been in use for many years in the packaging industry, it would appear that it is recently that such extruded zips have been suggested for use with garments.

WO97/07702 illustrates a double fastener integrating two types of fasteners, a toothed zip fastener and an extruded fastener, into a single assembly. The fastener in WO97/07702 is a continuous extruded zip consisting of a male zip track presenting a ball profile which can slide through and locate within a female zip track presenting channel profile corresponding to the ball profile. However in order for the holding strength of such zips to be sufficient to prevent their pulling apart such water proof fastener are often made of very stiff material. As such they do not provide significant stretchability and/or flexibility. Hence this may cause discomfort to the wearer wearing garments or footwear with such a zip or unattractively affect the appearance of the garment. The construction is bulky which greatly limits where and how it can be used.

U.S. Pat. No. 6,510,595 describes extruded profile zipper tracks which are an enhancement on the ball and cup like zipper tracks commonly used in packaging in that the profile of the interlocking profiles of each of the zipper tracks is such as to enhance the resistance to any lateral separation of the tracks. These zipper tracks are extruded from thermoplastic resins which have some flexibility but does not provide significant longitudinal stretchability. As a result of the forcing of the profiles to become merged and demerged, this prior art zipper trades-off two important aspects that are desirable in an extruded zip.

OBJECT OF THE INVENTION

Accordingly the present invention is directed towards and aims to provide improvements to zips which address the abovementioned disadvantages or to at least provide the public with a useful choice.

STATEMENT OF INVENTION

In a first aspect the invention provides a zip for use on garments, clothing, bags, safety wear and sports equipment, said zip comprising two mutually engagable zip tracks, each track attached to or integral with a tape, and a slider capable of moving along the zip tracks to merge or demerge the tracks, wherein a first of said zip tracks has a female profile defining a cavity with a zip slot extending along the length of the zip; and a second of said zip tracks has a male profile capable of fitting within and being retained by the female profile; and wherein the slider has guide means within the slider adapted to guide the male and female profiles towards one another for merging to allow the female profile to fit over and capture the male profile so that the two tracks are merged together into a closed state.

Preferably the guide means comprises substantially “Y” shaped passageways within the slider the entrance portions being male and female passageways respectively and adapted to allow the male and female profiles to pass therethrough, and an exit passageway for the merged profiles.

Preferably the guide means includes an expansion element adapted to open the slot of the female profile sufficiently to allow the female profile to fit over and capture the male profile so that the two tracks are merged together into a closed state.

More preferably the expansion element is located primarily within the female passageway

Alternatively where the male profile is generally wedge shaped in cross section having an apex and a base, with a tape or flange attached to or forming part of the base thereof, and the female profile is of a complementary wedge shape in cross section having an apex and a base, with a slot along the base of the female wedge shape then the components can be configured in such a way that an expansion element within the slider can be omitted. This is preferably achieved with a tape or flange attached to or forming part of the apex of the female wedge shape and the guide means within the slider having an entrance end and an exit end and including a male slot having an entrance aperture at the entrance end of the slider and adapted to allow passage of the male profile therethrough, and a female slot having an entrance aperture at the entrance end of the slider and adapted to allow passage of the female profile therethrough, the male and female slots extending from the entrance end of the slider towards one another and towards a merged slot which terminates at an exit aperture in the exit end of the slider and the male profile is adapted to penetrate and open the slot of the female member within the slider to allow the female profile to fit over and capture the male profile so that the two tracks are merged together into a closed state.

In another aspect the invention provides a zip for use on garments, clothing, bags, safety wear and sports equipment, said zip comprising two mutually engagable zip tracks, each track attached to or integral with a tape, and a slider capable of moving along the zip tracks to merge or demerge the tracks, wherein a first of said zip tracks has a female profile defining a cavity with the slot extending along the length of the zip; and a second of said zip tracks has a male profile capable of fitting within and being retained by the female profile; and wherein the slider has guide means within the slider adapted to guide the male and female profiles towards one another for merging, and an expansion element within said slider adapted to open the slot of the female profile sufficiently to allow the female profile to fit over and capture the male profile so that the two tracks are merged together into a closed state.

Preferably the male profile is of generally uniform cross section along the whole or part of its length.

Preferably the female profile is of generally uniform cross section along the whole or part of its length.

Preferably the guide means within the slider has an entrance end and an exit end and includes a male slot having an entrance aperture at the entrance end of the slider and adapted to allow passage of the male profile therethrough, and a female slot an entrance aperture at the entrance end of the slider and adapted to allow passage of the female profile therethrough, the male and female slots extending from the entrance end of the slider towards one another and towards a merged slot which terminates at an exit aperture in the exit end of the slider.

Preferably the slots within the slider are combined into a generally “Y” shape where the male and female slots combine to form the merged slot.

Preferably the male and female profiles have tapes extending from opposite edges thereof for connection to a garment or other substrate, and the slots within the slider have side slits to allow the slider to move along the tapes of the zip profiles.

Preferably the expansion element is located in the female slot and has a tapered portion facing towards the entrance end so that it can be located in the cavity of the female profile.

Preferably said expansion element is engaged to the body of said slider by a bridge which is located where the mouth of said female channel passes through the channel of said slider.

Preferably the male profile is generally wedge shaped with the tape attached to the base thereof and the female profile is of a complementary wedge shape with a slot along the base of the female wedge shape and the tape attached to the apex of the female wedge shape.

Preferably the expansion element in the female slot is of a tapered nature extending from its widest point at or near the merged slot, to a narrow end facing towards the entrance aperture of the female slot.

In another aspect the invention provides a slider for a zip of the type described above wherein the slider has guide means within the slider adapted to guide male and female zip profiles towards one another for merging, and an expansion element within said slider adapted to open the slot of the female zip profile sufficiently to allow the female zip profile to fit over and capture he male zip profile so that the two tracks are merged together into a closed state.

This slider and the male and female profiles can be configured to provide substantially water or fluid resistant zips and/or stretchable zips. Specific details of these two types of zips are contained in copending patent applications.

In the case of substantially water or fluid resistant zips the profiles can be continuous along the length of the zip unlike conventional toothed zips.

On the other hand, if they are to be configured to provide a stretchable zip then male and female profiles can be made from stretchable materials or one or other or both of them can be optionally segmented and attached to stretchable tapes.

In a further aspect the present invention consists in a zip substantially as described with reference to anyone of the accompanying drawings.

In another aspect the present invention consists in a slider for a zip substantially as described with reference to anyone of the accompanying drawings.

This invention may also be said broadly to consist in the parts, elements and features referred to or indicated in the specification of the application, individually or collectively, and any or all combinations of any two or more of said parts, elements or features, and where specific integers are mentioned herein which have known equivalents in the art to which this invention relates, such known equivalents are deemed to be incorporated herein as if individually set forth.

DESCRIPTION OF DRAWINGS

A preferred form of the present invention will now be described with reference to the accompanying drawings in which:

FIG. 1 is a plan view of a slider for use with the zip of the present invention showing in part in phantom, the guide tracks for the male and female profiles and the expansion element;

FIG. 2 is an end view of FIG. 1;

FIG. 3 is a view from the other (merged) end of FIG. 1;

FIG. 4 is a perspective view of the (optionally segmented) profiles of the male and female zip tracks of the zip,

FIG. 4A is a front view of a garment incorporating the zip as herein described,

FIG. 5 is a plan view of the slider of FIG. 1 engaged with the male and female zip tracks of FIG. 4 shown at and towards a first distal end of the zip tracks,

FIG. 6 is a sectional view through the slider showing the location of the expansion element in the female guide slot,

FIG. 7 is a side view of the slider of FIG. 1 and showing in part in phantom the guide track for the female profile zip track,

FIG. 7A is a sectional view through section AA of FIG. 7,

FIG. 8 is a side view of the male and female zip tracks at and towards a first distal end thereof,

FIG. 8A is a sectional view through section AA of FIG. 8,

FIG. 9 is a sectional view through section AA of FIG. 7,

FIG. 9A is a sectional view through section EE of FIG. 9,

FIG. 10 is a perspective view of the slider of FIG. 1,

FIG. 11 is a perspective view of the male and female profiles of the zip of Example 2,

FIG. 12 is a perspective view of the slider of Example 2,

FIG. 13 is a an expanded end elevation of the female profile;

FIG. 14 is an expanded end elevation of the male profile,

FIG. 15 is an expanded end elevation of the slider,

FIG. 16 is an elevation of the demerged end of the slider (reduced scale),

FIG. 17 top plan view of the slider of FIG. 16,

FIG. 18 is an end elevation of the merged (narrow) end of the slider of FIG. 16,

FIG. 19 is a cross-sectional view on line A-A showing the location of a “torpedo like” expansion means inside the slider (reduced scale),

FIG. 20 is a perspective view of optionally segmented male and female profiles attached to a flexible tape with each profile having an integral flange extending along its length, and the last segment of the female profile cut away to show the location of the male segments;

FIG. 21 is a cut-away perspective view of the expansion element of FIG. 19,

FIG. 21
a is a cross sectional view through FIG. 21 showing male and female guide slots and an expansion member in profile,

FIG. 22 is a perspective of the slider and pull tab;

FIG. 23 is a perspective of optionally segmented tracks showing their attachment to flexible tapes;

FIG. 24 shows partly split tracks,

FIG. 25 shows an interior plan view of a slider with an alternative more wedge shaped expansion element,

FIG. 26 is a cut-way perspective view of the slider and expansion element of FIG. 26,

FIG. 27 shows a lower end stop attached to a male track,

FIG. 28A shows a latch and panel arrangement to lock the lower ends of the zip together,

FIG. 28B shows their location at the bottom of a jacket type zip,

FIG. 29 is an expanded front elevation of the latch and pawl locked together,

FIG. 30 shows a zip with two sliders, and

FIG. 31 shows a modified optionally segmented male track where the male segments are substantially ellipsoidal in shape.

FIG. 32 shows a part section through a slider without an expansion element for use with the wedge shaped profiles of FIG. 11.

FIG. 33 shows a jacket with the zip closed and the slider near the top of the zip.

FIG. 34 shows a jacket with the zip open and the slider trapped on the female profile.

EXAMPLE 1

This example deals with a zip 101 and slider 115, which are provided as an alternative to a zip of a toothed kind, which may be incorporated in garments, articles of clothing, bags, clothing accessories or other.

ZIP TRACKS—The zip 101 consists of longitudinal zip tracks 102 and a zip slider 115. With reference to FIG. 4 the zip tracks 102 of the present invention are each substantially of a constant cross section along their entire length save for a series of gaps 180. The zip tracks 102 form part of or are secured to portions of a garment which are to have the ability of being connected and separated by the zip 101 of the present invention.

For example where the zip 101 of the present invention is incorporated in a jacket having an anterior positioned opening, the zip 101 may be incorporated to the two front panels of the anterior portion of the jacket to allow for the jacket to be opened and closed to provide an open end (jacket type) zip—see FIG. 4A.

MALE AND FEMALE TRACKS—The zip track 102 consists of a male zip track 103 and a female zip track 104. The male zip track 103 is primarily defined by its functional feature being a male profile 105 which is capable of merging and demerging with the female profile 106 of the female zip track 104 in a slider. At least the female profile 106 of the female zip track 104 is made of a material which is resiliently flexible. A suitable resilient material such as a plastics material is used for the purposes of defining the female profile 106 of the female zip track 104.

Each of the profiles 105, 106 are defined along a longitudinal edge 107 of a flange 108, 109 of the male zip track 103 and female zip track 104 respectively. Each flange 108, 109 is provided for the purposes of allowing the male zip track 103 and the female zip track 104 to be incorporated in a garment. The flanges 108, 109 are provided for the purposes of securing by stitching, ultrasonic welding, adhesive welding or the like to components of a garment.

The male zip track 103 and the female zip track 104 may be made from two separate items being the profiled features 105, 106 and the flanges 108, 109.

Alternatively the male zip track 103 and the female zip track 104 may each be made as a unitary item. The zip tracks 103, 104 are formed by injection moulding the segments about a tape.

Since the cross section of the male zip track 103 and the female zip track 104 are preferably substantially constant along their entire longitudinal (in direction LL) length, extrusion of the zip tracks 103, 104 is an appropriate manner for their manufacture.

Two Options:

The optional slots or gaps which are described below for the stretchable versions of this zip may be formed in one or both of the male and female zip track, after their being extruded. If the zip is intended to be substantially water resistant or provide a fluid barrier then it is preferable that both the male and female profiles are continuous along their length (not segmented) or the male profile may be partially segmented so long as it is contained fully within a continuous water impervious female profile.

SHAPE OF PROFILES—In this example the female profile 106 and male profile 105 are of a cup and ball shape. However alternative configurations of such profiles are also envisaged and the best profile that we have tested is that described in Example 2. It is a more oval or elliptical profile.

The female profile 106 includes a slot 110 which extends also in the longitudinal direction LL along the length of the female zip track 104. The slot is provided for the purposes of allowing the passing of the male profile 105 therethrough for the purposes of merging and demerging the male and female profiles 105, 106. The interior of the female profile 106 is preferably of shape complementary to the shape of the male profile 105 although this need not necessarily be so. Indeed as long as the interior and cross sectional shape of the female profile 106 is of a size larger than the male profile 105, then the male profile 105 can be comfortably received within the interior portion of the female profile 106.

SLIDER—In order to enhance the ease with which the merging of the male profile 105 with the female profile 106 can be achieved, the slider 115 is provided for the purposes of the merging and demerging of the male zip track 103 and female zip track 104. The slider 115 is an element which is graspable by the hands or fingers of a user and allows for the user to slide the slider in the longitudinal direction LL along the zip tracks 103, 104. It may have a pull tab attached thereto for ease of use.

The slider 115 is engaged with both the male zip track 103 and female zip track 104. Such engagement is as a result of the capturing of the profiles 105, 106 within guide slots 116, 117 of the slider 115. The guide slots are of a cross sectional shape (in a direction lateral to the longitudinal direction LL) sufficiently large enough to receive the respective profiles of the male zip track 103 and female zip track 104, yet confined enough for the purposes of preventing the profiles so captured within the guide slots 116 and 117 from separating form the slider in the transverse direction TT. The guide slot 116 for the female profile is in this example substantially of a circular (or one corresponding to the shape of the zip track profiles) cross section and likewise the guide slot 117 for the male profile is also of a substantially circular cross section along its length. Each slot includes an opening 118, 119 which allows the passing of the flange 108 and 109 respectively therethrough. The slider moving in the longitudinal direction LL along the zip track 102 manipulates the male zip track 103 and female zip track 104 relative to each other for the purposes of their merging and demerging.

At a first end 120 of the slider 115, the male and female zip tracks 103, 104 extend from the slider 115 in a separated condition. At a second end 121 of the slider 115, the male and female zip tracks 103, 104 extend from the slider 115 in a merged condition as for example shown in FIG. 5 transition between the first and second ends 120, 121 of the guide slots 116, 117 occurs which results in the bringing together of the profiles 106, 105 as a result of the merging of the guide slots 116, 117.

Preferably the slider 115 is provided with a spreader element, which is described in further detail with reference to Example 2 below. Preferably also, the cross sectional area of the female guide slot 116 expands as the slot extends in from each end of the slider 115, refer to the curves 270 detailed in FIG. 4 which show this increase in cross sectional area of the female guide slot 116. This expansion, and subsequent reduction, in cross sectional area of the female guide slot 116, when traveling from one end of the slot to the other, corresponds to some extent to the location and geometry of the spreader element which is located within the same slot. The change in cross sectional area is designed to accommodate expansion of the female profile 106 as it passes through the female guide slot 116 and is expanded by the expansion element.

OPTIONALLY SEGMENTED PROFILES—For the purposes of enhancing the longitudinal flexibility and also enhancing the stretchability in the longitudinal direction LL, at least the female profile 106 is defined by and made of a material which whilst of significantly high rigidity in order to allow for it to securely capture and resist removal of the male profile 105, it has a series of slots or gaps 180 provided spaced along its length.

The gaps extend preferably in a direction lateral to the longitudinal direction LL. Therefore the female profile 106 is not of a continuous and constant cross section (in the direction lateral to the longitudinal direction LL) since it is provided with a plurality of such gaps 180. The gaps 180 are preferably through the entire portion of the element defining the female profile 106 separating each of the profiles to define them as discrete items.

STRETCHABILITY OPTION—Where the female profiles 106 are provided as a series and/or an array of discrete items, the longitudinal stretchability of the female track 104 is no longer defined or limited by the nature of the material defining the female profile 106. It is then the nature of the material of for example the flange 109 or the material to which the flange is affixed, which limits the stretchability of the female track 104 in the direction LL.

Where the discrete female profiles 106 are disposed at an edge of a stretchable tape 109 e.g. made of a bias cut tape, neoprene, Lycra, spandex or other resilient material, the longitudinal stretchability of the female track 104 can be significant. The gaps 180 provided between adjacent discrete female profile elements 106 will expand and contract as and when the female track 104 is stretched and relaxed. In addition to enhancing the stretchability by the provision of gaps between the elements defining the female profile 106, the flexibility of the female track 104 will also be enhanced.

The amount of stretch along the length of the zip will be dependent upon the choice of the tape material and its stretchiness. We prefer to limit the stretchability of the zip (and hence the tape) to no more than 25% for most applications. For neoprene wetsuits a stretch factor of the zip of 15% to 20% is generally sufficient.

The gaps 180 may preferably completely separate those elements defining the female profile 106 but may in the alternative, only separate part of each of the elements defining the female profile 106. Where longitudinal stretchability is perhaps not an essential or desired feature, the elements defining the female profile 106 may still be attached at for example the base at where they are disposed along the edge of the flange 109. Bending out of the plane of the flange 109 is still able to be achieved where gaps are provided between those regions of the female profile 106 along the ridge 181. However for both flexibility and stretchability the elements defining the female profile 106 are discrete from each other. The gap 180 may be provided at regular intervals along the female track 104 or may be provided only at locations where the desired flexibility and/or stretchability are required.

Depending upon the application, we prefer that at least the female profile is made up of such discrete elements (since it needs to be of a material which has a high resistance to flexing for the purposes of ensuring that it can retain to a suitable amount, the engagement of the male profile 105). However the male profile 105 may likewise be provided as discrete segments as shown for example in FIG. 4. Whilst the male profile 105 need not be of a material of the same rigidity as that of the female profile 106 for the purposes of establishing a strong connection between the male and female profiles to resist its separation in a direction transverse to the direction LL, the gaps 180 provided along the male profile 105 will further enhance both the stretchability and flexibility of the zip tracks 102. The male profile 105 may likewise be attached to and be disposed at an edge of a flange or tape 108 of a material which will then define the deciding characteristics of the nature of the stretchability and flexibility of the male track 103. The flexibility of the tracks will be influenced by the size of the gap 180 hence the larger the gap the tighter the radius in which the male and female tracks can be bent.

The gaps 180 may be provided as a result of the female and/or male tracks 104, 103 being injection moulded. Alternatively where the female and/or male tracks 104, 103 or the profiles 105, 106 are extruded, the gaps 180 may be defined after extrusion. Laser cutting or machine cutting may be the most appropriate manner in which to define these gaps 180. Whilst as a result of the provision of the slots in both the female and male profile 106, 105, water tightness of the zip 101 may not be achievable; improvements in water tightness can be created by providing the slots 180 of the male profile 105 at different intervals than the gaps 180 of the female profile 106. Having the gaps 180 at different intervals will ensure that only a few gaps of each of the male and female profiles are at any one time, in register with each other. When they are in register with each other clearly no waterproof seal can be established between the male and female tracks 103, 104 at such a location.

Where the male profile 105 is of a continuous and constant cross section along its entire length, then a waterproof seal can be established between the male and female tracks 103, 104. Alternatively where the longitudinal relative positioning between the male and female tracks 103 and 104 is constantly repeatable such as for example where (a) the zip is closed end (trouser type) zip, or (b) the zip includes an end stop 184 as for example shown in FIGS. 4, 5 and 8, the gaps 180 of each of the male and female profiles 105, 106 can be provided so as to remain out of register. This end stop 184 can be a stopper or bung attached to the last female segment 181 to prevent the slider leaving that “upper” end of the female track.

Examples of Dimensions

It will be appreciated that the drawings are mostly on an enlarged scale, in order to illustrate the shapes, and functioning of the various components making up the zip fastener of this example. The zip fastener of this example can be made in various shapes, sizes and lengths to suit the end use of the product. However to appreciate the relative size of the components, we have given the following dimensions based on a prototype zip fastener designed for clothing for a typical zip length from 100 mm to 500mm. These dimensions are given purely by way of example only, and are not intended to be in any way limiting on the scope of the invention.

SliderLength 15 mminternal male track in slider = 2.25 mmWidest end 11.5 mminternal female track in slider = 3.75 mmNarrowest end 8 mminternal merged track in slider = 3.75 mmPull tab: 20 mm long by8 mm wideProfiles:Male profile height: 2.0 mmWidth at widest: 1.75 mmFemale profile height: 3.0 mmWidth at widest: 2.75 mm

EXAMPLE 2

This example is similar to example 1; save that the male member is shaped more like an arrow head, and the female member is more triangular in shape. The zip 201 consists of longitudinal zip tracks 202 and a slider 215. With reference to FIG. 11 the zip tracks 202 of the present invention are each substantially of a constant cross section along their entire length save for a series of gaps 280A. The zip tracks 202 form part of or are secured to portions of a garment which are to have the ability of being connected and separated by the zip 201 of the present invention. For example where the zip 201 of the present invention is incorporated in a jacket having an anterior positioned opening, the zip 201 may be incorporated to the two front panels of the anterior portion of the jacket to allow for the jacket to be opened and closed.

MALE AND FEMALE ZIP TRACKS—The zip track 202 consists of a male zip track 203 and a female zip track 204.

The male zip track 203 is primarily defined by its functional feature being a male profile 205 which is capable of merging and demerging with the female profile 206 of the female zip track 204.

Preferably at least the female profile 206 of the female zip track 204 is made of a material which is resiliently flexible. Depending upon the application a suitable plastics material or rubber material (or a composite of the two) may be used for the purposes of defying the female profile 206 of the female zip track 204. Suitable plastics materials can include polyethylene and polyvinylchloride. Other plastics can be used. Choice of plastic will depend on its properties and suitability for the end use, ease of moulding about a flexible tape, flexibility and stretchability as well as the desired tensile strength.

Each of the profiles 205, 206 are preferably defined along a longitudinal edge 207 of a flange 208, 209 of the male zip track 203 and female zip track 204 respectively. Each flange 208, 209 is provided for the purposes of allowing the male zip track 203 and the female zip track 204 to be incorporated in a garment. The flanges 208, 209 are provided for the purposes of securing by stitching, ultrasonic welding, adhesive welding or the like to components of a garment. The male zip track 203 and the female zip track 204 may be made from two separate items being the profiled features 205, 206 and the flanges 208, 209. Alternatively the male zip track 203 and the female zip track 204 may each be made as a unitary item. The zip tracks 203, 204 may be formed by extrusion, co-extrusion or be made by injection moulding. Since the cross section of the male zip track 203 and the female zip track 204 are preferably substantially constant along their entire longitudinal (in direction LL) length, extrusion of the zip tracks 203, 204 is an appropriate manner for their manufacture. The slots or gaps which are herein after described may be formed in one or both of the male and female zip track, after their being extruded

SHAPE OF PROFILES—A profile we have tested is shown in FIGS. 13 and 14. The male profile 205 looks a little like an arrowhead but it has a rounded nose. It leading edge is part of an ellipse. It has a pair of re-entrant flanges at rear. The female profile 206 includes a slot 210 which extends also in the longitudinal direction LL along the length of the female zip track 204. The slot is provided for the purposes of allowing the passing of the male profile 205 there through for the purposes of merging and demerging the male and female profiles 205, 206. The interior of the female profile 206 is complementary in shape to the shape of the male profile 205. The female profile provides a continuous (or semi-continuous) cavity of a cross-sectional shape corresponding to but slightly larger than the dimensions of the male profile.

The re-entrant nature of the jaws 211 of the female profile 206 co-acting with the flanges 212 of the male profile 205 in a 50 mm length of a first prototype had a tensile strength (resistance to being pulled apart at right angles to the length of the zip) of over 15 kgs. This tensile strength can be varied by suitable design of the profile shapes and choice and flexibility of materials used in the manufacture of the zip. In some cases a low tensile strength may be an advantage (for safety) in other cases a high tensile strength may be desirable.

SLIDER: In order to enhance the ease with which the merging of the male profile 205 with the female profile 206 can be achieved, the present invention incorporates a slider 215 for the purposes of the merging and demerging of the male zip track 203 and female zip track 204.

The slider 215 (refer to FIG. 22) has a pull tab 231 hingedly connected to an external boss 230 and is designed to be graspable by the hands or fingers of a user and allows for the user to slide the slider in the longitudinal direction LL along the zip tracks 203, 204. The slider 215 is engaged with both the male zip track 203 and female zip track 204. Such engagement is as a result of the capturing of the profiles 205, 206 within guide slots 217, 216 of the slider 215.

The guide slots are of a cross sectional shape (in a direction lateral to the longitudinal direction LL) sufficiently large enough to receive the respective profiles of the male zip track 203 and female zip track 204, yet confined enough for the purposes of preventing the profiles so captured within the guide slots 216 and 217 from separating from the slider in the transverse direction TT. The guide slot 216 for the female profile as shown in FIG. 15 is of a shape corresponding to the shape of the female profile 206 shown in FIG. 13. Similarly the guide slot 217 for the male profile is of a shape corresponding to the shape of the male profile 205 shown in FIG. 14.

It will be noted that the cross sectional area of the female guide slot is larger about the torpedo shaped expansion element 226 to allow for expansion of the female profile as described below. Refer also to the curves 270 detailed in FIG. 4 which show how the cross sectional area of the female guide slot increases as it extends from each end of the slider 115. This is also evident in the modified slider 226A shown in FIG. 25.

FIG. 21
a shows the male and female guide slots 216 and 217 and the expansion member 226 in profile, in a cross sectional view. It can be seen in this drawing that the bridge 228 attaches the expansion member 226 to the central island portion 227. The central island portion 227 is essentially the material of the slider 215 which is between the male and female guide slots 216 and 217. In this view the male and female guide slots 216 and 217 can be seen diverging as they extend away from the bifurcation area (not shown) towards the first end 220 of the slider 215.

The female guide slot 216 may be straighter than the male guide slot 217, as the female profile 206 because of its size and shape may be less flexible than the male profile 205, and may, depending upon design parameters be less able to accommodate as much of a bend within the slider guide tack as would the male member. However in some cases it may be desirable to make the guide slots of the same length to minimize differential drag between the profiles and the slider which may result in twisting of the slider.

Each slot includes an opening 218, 219 which allows the passing of the flange 208 and 209 respectively there through.

The slider moving in the longitudinal direction LL along the zip track 202 manipulates the male zip track 203 and female zip track 204 relative to each other for the purposes of their merging and demerging. At a first end 220 of the slider 215, the male and female zip tracks 203, 204 extend from the slider 215 in a separated condition as shown in FIGS. 20 and 30.

At a second end 221 of the slider 215, the male and female zip tracks 203, 204 extend from the slider 215 in a merged condition as for example is shown in FIG. 20. A transition between the first and second ends 220, 221 of the guide slots 216, 217 occurs which results in the bringing together of the profiles 205, 206 as a result of the merging of the guide slots 216, 217. Hence extending from the second distal end 221 where the guide slots 216 and 217 are merged, towards the first distal end 220, the guide slots 216 and 217 bifurcate.

Extending immediately along the guide slot 216 for the female profile beyond the region 225 thereof where bifurcation is initiated the guide slot 216 for the female profile incorporates a torpedo like expansion element 226.

The expansion element 226 is disposed within the guide slot 216 in a region thereof immediately adjacent to the bifurcation initiation zone 225. The expansion element 226 is an elongate element extending in the direction of the guide slot 216. The expansion element 226 is of a profile which at least immediately adjacent the bifurcation zone 225 results in the expansion of the slot 210 to the extent that it opens sufficiently to receive and allow the passing there through of the male profile 205 of the male zip track 203. The cross section of the expansion element 226 corresponds to the cross section of the female profile. The shape of the expansion element is shown in more detail in FIG. 21.

This expansion initiated by the sliding of the slider 215 in a direction advancing the first distal end 220 as the leading edge of the slider 215, will result in the progressive traveling of the expansion element 226 along and within the female profile 206 and as the female profile 206 passes over the expansion element 226 the female profile 206 is opened to expand the slot 210 sufficiently to allow the male profile 205 to pass there through with a reduced requirement for the pressing of the male profile 205 into the slot 210. In the most preferred form the slot 210 is opened to a size slightly larger than the thickness of the male profile 205 so that no pressing of the male and female profiles 205, 206 together is necessary to establish a merged condition therebetween.

The expansion element 226 is of a tapered nature extending from its widest point at or near the bifurcation zone 225, to a bullet shaped end 229 towards the first distal end 220 of the slider 215. Such a tapered profile will allow for the gradual expansion of the female profile 206 as the slider is advanced in the direction to merge the male and female profiles 205, 206.

The expansion element 226 is attached to a central island 227 of the slider by a bridge member 228, see FIG. 21. The bridge 228 is of a size which allows it to pass through the slot 210 of the female profile 206.

In the most preferred form of the present invention the female guide slot 216 for the female profile 206 is not of a constant cross section along its length between the first distal end 220 and at least the bifurcation zone 225. Most preferably the female guide slot 216 expands from a smaller cross section at the first distal end 220 to a slightly larger cross section in the portion of the female guide slot 216 which surrounds the expansion element 226. See the curves 270 shown in FIG. 7 which illustrate this gradual increase in cross sectional area of the female guide slot, as the slot extends in from each end of the slider 115.

Such expansion can also be seen with reference to FIG. 9A. The expansion of the guide slot 216 is commensurate with the expansion in the shape of the female profile 206 as it progresses along the guide slot 216. Whilst a constant cross section of a shape commensurate with the female profile when in a fully expanded condition may be appropriate along the entire length of the guide slot 216, it is preferred, and in order to ensure that the female profile remains well captured within the guide slot 216, that the cross section does vary over the length of the guide slot 216.

In order for contact to be maintained by the expansion element 226 with the female profile 206 over a distance for as long as practically possible prior to the merging of the female profile with the male profile, it can be seen that the expansion element 226 extends at least in part into the path of the male profile defined by the guide slot 217.

The end of the expansion element 226 nearest the second end 221 preferably includes a cut out 238 which is of a shape to allow the passing, there adjacent of, of the male profile 205. However once the male and female profiles are merged substantially in the merged zone 239 of the then non-bifurcated guide tracks 216, 217, no influence of the expansion element 226 is necessary for the female profile 206. It will be appreciated that whilst in the main there has been reference made herein to the merging of the male and female profiles, a demerging of the male and female profiles operates in substantially the reverse manner to that which has herein been described, that is, the spreader expands the female profile 206 away from the male profile 205 in the area where the guide slots 216 and 217 bifurcate.

DEMERGING: When the zip is closed the top of the male and female profiles will extend from the first end 220 of the slider (in that sense a jacket zip is never fully closed as a small portion of the male and female profiles will always be unmerged—unlike the face to face seals inside zip lock plastic bags. Consequently downward movement of the slider along the zip will cause the male and female profiles to pass through the guide slots and demerge whether or not there is an expansion element in the female guide slot. Nevertheless by suitable shaping of the end of the expansion element facing end 221 it is possible to assist the demerging operation and help the female profile to open up as it moves away from the male member where the guide slots separate. By suitably spacing the shaped expansion element away from the side of the guide track by a thin bridge it is possible for the jaws of the female profile to fit around the bridge portion as it relaxes into the demerged state, so that the bridge portion is thin enough to pass through slot 210 of the female profile.

In the demerging of the male and female profiles, the advanced most edge of the slider is the second end 221. The slider 215 will always remain in contact with the male and female guide tracks 203 and 204 and when the zip tracks 202 are in a fully merged condition along substantially their entire length, the slider will be provided at the upper end of the zip tracks 202.

The slider is preferably injection moulded from a low friction plastics material, such as PTFE (polytetrafluoroethylene), to allow ease of movement of the slider and the insertion of the expansion element into the female profile.

Another form of expansion element is shown in FIGS. 25 and 26. It is a sharper wedge shape designed to penetrate the slot and interior of the female profile and allow it to expand sufficiently to snap over the male profile.

End stops may be provided on the zip tracks to prevent the slider 215 from sliding beyond and off the zip tracks 202. Progression of the slider 215 towards the other end of the zip tracks 202 will result in the male and female profiles 205, 206 demerging.

OPTIONALLY SEGMENTED PROFILES—For the purposes of enhancing the longitudinal flexibility and preferably also enhancing the stretchability in the longitudinal direction LL at least the female profile. 206 is defined by and made of a material which whilst of significantly high rigidity in order to allow for it to securely capture and resist removal of the male profile 205, which has a series of slots or gaps 280 provided spaced along its length.

The gaps 280 extend preferably in a direction lateral to the longitudinal direction LL. Therefore the female profile 206 is not of a continuous and constant cross section (in the direction lateral to the longitudinal direction LL) since it is provided with a plurality of such gaps 280 but it is repetitive. The gaps 280 are preferably through the entire portion of the element defining the female profile 206 separating each of the profiles to define them as discrete items. Where the female profiles 206 are provided as a series and/or an array of discrete items, the longitudinal stretchability of the female track 204 is no longer defined or limited by the nature of the material defining the female profile 206. It is then the nature of the material of for example the flange 209 or the material to which the flange is affixed, which limits the stretchability of the female track 204 in the direction LL.

Where the discrete female profiles 206 are disposed at an edge of for example a neoprene or Lycra material flange 209, the longitudinal stretchability of the female track 204 will be significant. The gaps 280 provided between adjacent discrete female profile elements 206 will expand and contract as and when the female track 204 is stretched and relaxed. In addition to enhancing the stretchability by the provision of gaps between the elements defining the female profile 206, the flexibility of the female track 204 will also be enhanced. The gaps 280 may preferably completely separate those elements defining the female profile 206 but may in the alternative, only separate part of each of the elements defining the female profile 206. Where longitudinal stretchability is perhaps not an essential or desired feature, the elements defining the female profile 206 may still be attached at for example the base at where they are disposed along the edge of the flange 209. Bending out of the plane of the flange 209 is still able to be achieved where gaps are provided between those regions of the female profile 206 along the ridge 281. However for both flexibility and stretchability the elements defining the female profile 206 are discrete from each other.

The gap 280 may be provided at regular intervals along the female track 4 or may be provided only at locations where the desired flexibility and/or stretchability are required.

Whilst most importantly it is the female profile which is preferably of such discrete elements (since it needs to be of a material which has a high resistance to flexing for the purposes of ensuring that it can retain to a suitable amount, the engagement of the male profile 205) therewith the male profile 205 may likewise be provided as discrete segments as shown for example in FIGS. 20 and 21. Whilst the male profile 205 need not be of a material of the same rigidity as that of the female profile 206 for the purposes of establishing a strong connection between the male and female profiles to resist its separation in a direction transverse to the direction LL, the gaps 280 provided along the male profile 205 will further enhance both the stretchability and flexibility of the zip tracks 202. The male profiles 205 may likewise be attached to and be disposed at an edge of a flange 208 of a material which will then define the deciding characteristics of the nature of the stretchability and flexibility of the male track 203. Clearly the flexibility of the tracks will be limited by the size of the gap 280 hence the larger the gap the tighter the radius in which the male and female tracks can be bent.

The gaps 280 may be provided as a result of the female and/or male tracks 204, 203 being injection moulded. Alternatively where the female and/or male tracks 204, 203 or the profiles 205, 206 are extruded, the gaps 280 may be defined after extrusion. Laser cutting or machine cutting may be the most appropriate manner in which to define these gaps 280. Whilst as a result of the provision of the slots in both the female and male profile 206, 205, water tightness of the zip 201 may not be achievable; improvements in water tightness can be created by providing the slots 280 of the male track 205 at different intervals than the gaps 280 of the female profile 206. Having the gaps 280 at different intervals will ensure that only a few gaps of each of the male and female profiles are at any one time, in register with each other. When they are in register with each other clearly no waterproof seal can be established between the male and female tracks 203, 204 at such a location.

Where the male profile 205 is of a continuous and constant cross section along its entire length, then a waterproof seal can be established between the male and female tracks 203, 204. Alternatively where the longitudinal relative positioning between the male and female tracks 203 and 204 is constantly repeatable such as for example where the zip includes an upper end stop, the gaps 280 of each of the male and female profiles 205, 206 can be provided so as to remain out of register.

CLOSED END ZIPS: If the zip fastener is intended as a closed end zip such as a trouser zip (or a bag zip), one end of the two profiles can be joined together in a suitable fashion typically by sewing in a similar fashion to prior art zippers. End stops may be provided at the other end (top) of the profiles to trap the slider on at least one of the profiles. In most cases this will be the female profile.

OPEN END ZIPS (Jacket type zips): Where the two profiles are not joined together to allow full separation as is the case with a jacket type zip then end stops can be provided at each end of the zip profiles. Preferably at least one end of the profiles has mean for locking the zip tracks together to prevent longitudinal movement of the male track sliding within and then out of the female track when the zip is closed.

Any type of end stop can be used to keep the slider on the tracks and align the two ends of the zip tracks. Conventional lower end stop designs can be used. A novel end stop will now be described. This end stop design is a “locater” and is designed to stop longitudinal movement of the male and female tracks relative to one another.

LOWER END STOPS: Since the male and female zip tracks 103, 104 are of a kind which are of generally uniform or repeating profiles along their length, the zip tracks provide no resistance beyond that provided as a result of friction, to longitudinal sliding relative to each other in the direction LL.

Where the zip 101 is to be incorporated in for example a jacket, refer FIG. 28B, a complete separation of the zip tracks needs to be capable of being provided. As such it is not possible to permanently lock the male and female zip tracks 103, 104 together at for example one of the ends of the tracks (as is the case with closed zips such as trouser zips).

A temporary means of fastening the tracks to prevent their relative movement in the longitudinal direction is however desired so that the garment can remain in alignment.

One way of achieving this is to incorporate at one end of the zip track 102, a zip stop 160 as shown in FIG. 29. The zip stop 160 consists of a latch 168, and a pin box 161 which may be of a kind similar to those found on tooth like zip tracks (we have used the term “pin box” to designate this part as it appears in a similar location to the pin box of a conventional toothed zip fastener but our pin box performs a different function and is of a different shape.

The pin box 161 is incorporated at the end of one of the male and female zip tracks 103, 104, (preferably to the female zip track 104 as shown in FIG. 28A) and extends in a manner therefrom to present an interference to the movement of the male zip track 103 in the longitudinal direction advancing it beyond the end 162 of the female zip track 104. It may also incorporate a slot 165 or rebate or recess for the purposes of receiving the distal end 166 of the male zip track 103.

The slot 165 is provided in a configuration to discourage or prevent the separation of the male zip track 103 from the female zip track 104 in a direction transverse to the longitudinal direction LL.

The distal end 166 of the male zip track 103 is hence captured and prevented from movement in a direction transverse to the longitudinal direction LL once received within the slot or recess 165. The slot or recess 165 is of a shape which includes a region commensurate with the male profile 105 of the male track 103 and includes an opening to exterior thereof, through which the flange 108 of the male zip track can pass. With the provision of the pin box 161 to one of the male and female zip tracks 103, 104, movement of the male and female zip tracks in one direction of the longitudinal directions LL is able to be prevented.

However without any further enhancement, it is still possible for relative movement in an opposite direction along the axis LL to occur between the male and female zip tracks 103, 104. This direction would be to separate the engagement of the end 166 of the male zip track 103 from within the slot 165 of the pin box 161.

In order to prevent the movement of the male zip track 103 in that direction, the male zip track 103 is provided with a latch 168 which is capable of being located with a catch 169 of for example the pin box 161. The latch 168 includes a surface for mutual engagement with a surface of the catch 169 when the distal end 166 of the male zip track 103 is located adequately or to its full extent, within the recess 165 in its longitudinal direction LL.

The catch 169 becomes engaged with the latch 168 in a manner to prevent the retraction of the distal end 166 from the slot 165 of the pin box 161. The arrangement of the latch 168 and catch 169 is preferably for it to act in a snap fit like manner. As the male zip track 103 is advanced for the engagement of its distal end 166 within the slot 165 by its movement in the direction LL relative to the female zip track 104, the catch 169 is also advanced in the direction LL until its alignment with the catch 169 whereupon it will snap into an interference relationship therewith.

The catch 169 includes a profiled surface 170 which is provided for the purposes of allowing for the catch 169 to be displaced in a direction transverse to the longitudinal direction LL as it is progressed for engagement of the distal end 166 into the slot 165. The profiled surface 170 is for example a tapered or curved surface which presents no significant resistance to its movement and the movement of the male zip track 103 in the longitudinal direction to establish an engagement of the distal end 166 within the slot 165. The latch 168 is hence made from a resiliently flexible material which is capable of moving in the direction transverse to the direction LL so as to allow for it to be advanced and establish the interference like fit with the catch 169 of the pin box 161.

To allow for the disengagement of the latch 168 with the catch 169, the latch 168 includes a graspable end 171 presented to allow for a finger of a user to manipulate the latch 168 for the purposes of its disengagement with the catch 169. The end 171 is hence presented to allow for the displacement of the latch 168 by a finger of the user in a direction transverse to the longitudinal direction LL to slide the interference surfaces of the catch 169 and latch 168 to thereby allow for the male zip track 103 to remove itself from engagement with the slot 165.

The end 171 of the latch 168 protrudes or projects sufficiently for convenient grasping or at least engagement by a finger of a user for the purposes of allowing the disengagement of the latch 168 with the catch 169. Whilst in the most preferred form and as herein shown, the pin box 161 is provided at the end of the female zip track 104, it may alternatively be provided at the end of the male zip track 103 and the latch 168 may be provided to the female zip track.

The size and shape of this end stop 160 allows for the placement of an aperture 190 passing through the pin box 161 for attachment of a ski pass or other ticket or identification tag.

In order to enhance the ease with which the merging of the male profile 105 with the female profile 106 can be achieved, the present invention may incorporate a slider 115 for the purposes of the merging and demerging of the male zip track 103 and female zip track 104.

The slider 115 is an element which is graspable by the hands or fingers of a user and allows for the user to slide the slider in the longitudinal direction LL along the zip tracks 103, 104. The slider 115 is engaged with both the male zip track 103 and female zip track 104. Such engagement is as a result of the capturing of the profiles 105, 106 within guide slots 116, 117 of the slider 115.

The guide slots are of a cross sectional shape sufficiently large enough to receive the respective profiles of the male zip track 103 and female zip track 104, yet confined enough for the purposes of preventing the profiles so captured within the guide slots 116 and 117 from separating form the slider in the transverse direction TT. The guide slot 116 for the female profile is substantially of a part elliptical cross section and likewise the guide slot 117 for the male profile is also of a substantially part elliptical cross section along its length so that they correspond to the shape of the two profiles.

Each guide slot 116 and 117 includes an opening 118, 119 which allows the passing of the flange 108 and 109 respectively therethrough. The slider moving in the longitudinal direction LL along the zip track 102 manipulates the male zip track 103 and female zip track 104 relative to each other for the purposes of their merging and demerging. At a first end 120 of the slider 115, the male and female zip tracks 103, 104 extend from the slider 115 in a separated condition. At a second end 121 of the slider 115, the male and female zip tracks 103, 104 extend from the slider 115 in a merged condition as for example shown in FIG. 5. A transition between the first and second ends 120, 121 of the guide slots 116, 117 occurs which results in the bringing together of the profiles 105, 106 as a result of the merging of the guide slots 116, 117.

The opening for the tracks at end 121 of the slider is optionally off-set from its centreline to allow the latch 168 to pass external of the slider. To prevent a clashing of the latch 168 with the slider the latch is also off-set from its male track 105 by a distance X as shown in FIG. 29 and is preferably attached to the tape or flange of the male profile so that it can bypass the slider when the end of the male profile is inserted into the slider.

The gap between the end of the male track 105 and the latch 168 is sufficient to allow the slider 115 to pass there through.

PARTIAL SLITS—With reference to FIG. 24 there is shown a modification to the otherwise constant cross section female profile 206A. In this instance there are gaps or relief slots 280A formed not entirely through the female profile. The slots 280A are provided through the female profile with a view to weakening its bending moment strength in a direction normal to the plan of the flange or tape 209 for the enhancement of the flexibility of the female zip. In this way the female profile need no longer consist of discrete elements as shown in FIG. 23 as the female profile is weakened to allow for easier bending in a plane extending longitudinally and perpendicular to the plane of the flange 209. It will be appreciated that in this configuration, the material of the female profile will be influential in the nature of the stretchability of the female zip track since the female profiles are not separated elements.

ELLIPSOIDAL MALE SEGMENTS—With reference to FIG. 31 there is shown a modification to the shape of the male segments 305. In this version the segments are generally ellipsoidal in nature. By rounding the ends of the male segments 205 it is possible to allow for larger gaps between both the male and female segments to enhance stretchability and flexibility whilst minimizing the risk of the leading edge of the male segments 305 from catching in the gap 380 between the female segments 306.

Although we prefer to manufacture the male and female segments from a plastics material it is possible (though unlikely) that the male segments (especially these ellipsoidal segments 305) could be made of metal and crimped onto the tape.

Modified Slider for Use with Wedge Shaped Profiles.

Where the profiles of at least the male member is wedge shaped so that it has a narrow apex along its length capable of penetrating the slot of the female profile then the expansion element can be omitted. FIG. 32 is a part sectional view of a slider without an expansion element showing short sections of the profiles entering the slider and a short length of the merged profiles leaving the sliding. In accordance with the convention we have used in these drawings the female profile is shown on the right of the slider and the male profile on the left of the slider. By considering the substantially “Y”-shaped tracks and the merge angle it will be noted that the relative size, shape and “sharpness” of the male profile will allow it to penetrate the female profile even in its “closed” state. As it enters the slot the shape of the male profile will allow it to wedge the female profile open within the confines of the larger cavity of the merged track so that the two profiles are moved together on essentially curved paths which are partly determined by the geometry of the tracks within the slider. All this happens as the slider moves up a jacket zip of the type shown in FIG. 33. Demerging occurs when the slider is moved down the zip and the bottom end of the male profile is removed from the slider. The bottom of the male profile is configured as shown in FIG. 33 so that it is easy to insert the male profile into the slider to reconnect the zip. The top and bottom of the female profile has end stops to retain the slider on the female profile. The top of the male profile may also have an end stop.

In most cases the apex of the male profile will be rounded but the body will be generally wedged shaped as we have found that this is the most effective shape for the male profile.

In most cases there is an advantage in having an integral plastics flange extending from at least the bottom end of the male profile as this helps provide a stiff enough substrate for the latch of the end stop and also a stiff enough portion to assist in holding the bottom of the male profile as it is inserted into the slider.

Examples of Dimensions

It will be appreciated that the drawings are mostly on an enlarged scale, in order to illustrate the shapes, and functioning of the various components malting up the zip fastener of this example. The zip fastener of this example can be made in various shapes, sizes and lengths to suit the end use of the product. However to appreciate the relative size of the components, we have given the following dimensions based on a prototype zip fastener designed for clothing for a typical zip length from 100 mm to 500 mm. These dimensions are given purely by way of example only, and are not intended to be in any way limiting on the scope of the invention.

SliderLength 15 mminternal male track in slider 2.5 mmWidest end 11.5internal female track in slider = 4 mmNarrowest end 8 mminternal merged track in slider = 4 mmPull tab: 20 mm long by5 mm wideProfiles:Male profile height: 1.5 mmWidth at widest: 2.0 mmFemale profile height: 2.5 mmWidth at widest: 3.0 mm

INDUSTRIAL APPLICATION

The invention relates to a novel zip fastener particularly suited for use in the manufacture of clothing, as well as for bags and footwear.

Advantages

The novel zip fastener of these examples can be designed to stretch, or to be substantially water resistant. These advantages derive from the design of the slider and the shape of the male and female profiles. The slider has guide means within the slider adapted to guide the male and female profiles towards one another for merging to allow the female profile to fit over and capture the male profile so that the two tracks are merged together into a closed state.

The shape of the male profile and/or the optional expansion element in the slider allows the female profile to be opened and slid over the male profile without excessive force and without the need to apply force to close the female profile. The resilient nature of the female profile will allow it to spring back into its resting state and close about and retain the male profile trapped inside after merging has taken place.

The male and female profiles may be formed from different materials or have different properties. They can be injection moulded about reel fed tapes. The relative size and relative friction or stiction of the male and female profile may be such that once merged relative sliding of the two profiles is difficult so that the tracks are held in place. Or end stops can be used to anchor at least one end of the tracks to prevent relative sliding of the tracks.

The continuous nature of the new zips described herein can provide less drag than, for example a toothed zipper. This feature could be significant especially for zips used on clothing for athletes who require minimum drag, for example swimmers, skiers and triathletes.

The prior art zips have to either be soft enough to allow for the profiles to slip into place without requiring significant force to push the profiles together but this simultaneously limits or reduces the resistance to the lateral separation of the tracks. Should the strength of the material be enhanced, then despite the fact that the resistance to lateral separation will be increased, the longitudinal stiffness of the zip will also increase. Where a zip is incorporated in a garment it is desirable for the longitudinal stiffness to not be so significant as to alter significantly, the appearance of the garment or to make its use or comfort more limited or reduced.

Variations

Whilst we have illustrated two different configurations of male and female profiles, it will be appreciated that a number of different, and preferably complementary shapes could be used for the male and female profiles, depending upon the degree of tensile strength required when a force is applied to either side of the zip fastener to pull it apart, as well as the resilience of the zip fastener and the profiles thereof to accommodate bending or flexing transversely to the main axis of the zip fastener. As for example when the fabric is pulled or pushed at right angles to the longitudinal axis of the zip, or the components of the zip fastener pass through the slider to merge or demerge. The size of shape of the male and female profiles, the design properties of the materials used, for example the type of plastics used, and the way that the profiles are formed either by injection moulding, or by extrusion, or by some other process, can be varied through different applications, production volumes, or different designs of a zip fastener for particular purposes.

By using different properties or materials for the male and female profiles and having different flanges or by attaching the profiles to different tapes, one side of the zip could be adapted to be attached to a stiff fabric such as denim whilst the other side of the zip could be attached to a stretchable fabric such as Lycra or Neoprene.

Although in the main examples we have mentioned the use of plastics material for the different profiles, it is equally possible that the profiles could be formed of a neoprene rubber or the like, and could be moulded about a resilient tape, the resilient tape preferably having the similar stretch characteristics as the fabric to which it is to be attached. For example if the zip fastener is to be attached to a Lycra garment, it is preferable that the tape forming part of the zip fastener of this invention be also formed of Lycra having the same or lesser stretch characteristics as that of the fabric to which it is to be attached. In some cases it may be desirable to use a tape which has a greater degree of stretchability than the fabric to which it is to be attached, because the moulding of the various male and female profiles or segments thereof to the tape may result in a slight stiffening of the overall zip fastener, to bring it back to the same degree of stretch as the fabric to which it is to be attached.

Although we have mentioned polyethylene and polyvinylchloride as preferred plastics materials for the male and female profiles, it will be appreciated that there are various other plastics materials may be used depending upon the application, for example the components could be formed of nylon, polytetraethylene (PDFE), low density polyethylene (LDPE), high density polyethylene (HDPE) and various other industrial plastics.

Although the stretchable optionally segmented zip is best made by injection moulding the individual segments onto a supply of tape, it is possible that by using a resilient plastics or rubber material for the male and female profiles that a stretchable zip could be made by extrusion or co-extrusion.

Although in most cases the slider will be made from a hard plastics material, it is also possible to make all or part of the slider from other materials, and in particular from metal. The slider of this invention typically has a shallower entrance angle than conventional sliders used with toothed zips where the teeth have to be meshed together.

Finally, it will be appreciated that various other alterations or modifications may be made to the foregoing without departing from the scope of this invention.

Number	Date	Country	Kind
534603	Aug 2004	NZ	national
534601	Aug 2004	NZ	national
534602	Aug 2004	NZ	national

Zip Fastener and Slider

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