Patent Document

FIELD OF THE INVENTION 
       [0001]    The present invention relates to the field of zippers. In particular, the present invention relates to the field of waterproof zippers. 
       BACKGROUND OF THE INVENTION 
       [0002]    A zipper is a popular device for temporarily joining two edges of a fabric. Zippers include two tapes, each having dozens or hundreds of metal or plastic teeth. A manually operated slider joins and separates the teeth, according to the sliding direction. 
         [0003]    Zippers have the advantage of speed and ease of joining the two sides, compared to fastening laces or buttons. 
         [0004]    In addition, zippers offer improved sealing, and as such, are used in raincoats. An additional improvement of the sealing feature of zippers includes coating a zipper&#39;s tape with sealing material. 
         [0005]    One of the drawbacks of the prior art zippers is that the coating of a zipper does not seal the zipper as a whole, i.e. the teeth and other areas remain uncovered. As a result, water penetrates between the teeth, or between the tape and the teeth. 
         [0006]    Prior art solutions of coating the teeth prior to grasping the teeth to the tape commonly require separation of each tooth to one unit above the tape and another below the tape, and engaging the two units through the tape. 
         [0007]    However, these zippers are disadvantaged by non-firm grasping of the teeth to the tape. 
         [0008]    It is an object of the present invention to provide a waterproof zipper, having improved sealing in comparison to the prior art. 
         [0009]    Other objects and advantages of the invention will become apparent as the description proceeds. 
       SUMMARY OF THE INVENTION 
       [0010]    In one aspect, the present invention is directed to a waterproof zipper ( 2 ) comprising:
       joining teeth ( 6 ), each consolidated by a consolidating block ( 24 ) and contactably grasping the tape ( 4 ) of the zipper ( 2 ), separating the tape ( 4 ) from the opposite tape of said zipper; and   a soft seal ( 8 ), wrapping and expanding (towards  48 ) each of the two tapes ( 4 ) beyond the joining line ( 78 ) of the tapes ( 4 );
 
thereby applying pressure between the soft seals ( 8 ) at the joining line ( 78 ), resulting in tight sealing of the two soft seals ( 8 ).
       
 
         [0013]    The soft seal ( 8 ) preferably penetrates into ( 30 ,  24  in  FIG. 7 ) each of the teeth ( 6 ), beyond the thickness of said consolidating block ( 24 ) of each of said teeth (i.e to the distance between  80  and  80 ). 
         [0014]    The soft seal ( 8 ) preferably expands between ( 38  in  FIG. 6 ) adjacent teeth ( 44 , 46 ) of the tape. 
         [0015]    Each of the joining teeth ( 6 ) may comprise a slot ( 30 ) at the joining unit ( 22 ) thereof, allowing the penetration of the soft seal ( 8 ) therein. 
         [0016]    The distance between reeds ( 26 , 28 ) of the slot ( 30 ) preferably is larger than the thickness of the consolidating block ( 24 ) of the teeth ( 6 ), for allowing the penetration of the soft seal ( 8 ) into the slot ( 30 ) beyond the thickness of the consolidating block ( 24 ). 
         [0017]    The zipper may further comprise an upper stair ( 80 ) and a lower stair ( 80 ) between the slot ( 30 ) and the consolidating block ( 24 ). 
         [0018]    The material of the soft seal ( 8 ) may comprise Thermoplastic Elastomer (TPE). 
         [0019]    The soft seal ( 8 ) may further comprise a stamp ( 32 ), for providing information. 
         [0020]    In another aspect, the present invention is directed to a method for manufacturing a waterproof zipper ( 2 ) comprising the steps of:
       inserting (step  4 ) into a mold ( 62  in  FIG. 11 ) a tape ( 4 ) of a zipper (may be  12 ) grasped with teeth ( 6 ); and   injecting (step  5 ) a liquid seal ( 84 ) into the mold ( 62 ), thereby providing a soft seal ( 8 ) wrapped on the tape and teeth.       
 
         [0023]    The method may further comprise the step of inserting a mold insert ( 68 ) into a slot ( 30 ) of each of the teeth such that the injection is beyond the joining line ( 78 ) between that tape and the opposite tape. 
         [0024]    The inserting step of said tape into said mold may comprise spacing ( 74 ) between the tape ( 4 ) and the mold ( 62 ). 
         [0025]    The injecting step may comprise penetrating the liquid seal into each of the teeth beyond the thickness of the consolidating block of each of the teeth. 
         [0026]    The injecting step may comprise expanding the liquid seal between adjacent teeth of the tape. 
         [0027]    The tape inserted into the mold may be non-waterproof. 
         [0028]    The injecting step may comprise stamping information. 
         [0029]    The foregoing embodiments of the invention have been described and illustrated in conjunction with systems and methods thereof, which are meant to be merely illustrative, and not limiting. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0030]    Embodiments and features of the present invention are described herein in conjunction with the following drawings: 
           [0031]      FIG. 1  is a side view of a zipper according to one embodiment of the present invention. 
           [0032]      FIG. 2  is a side view of a non-waterproof zipper. 
           [0033]      FIG. 3  shows a tape of the non-waterproof zipper and of the zipper of the present invention. 
           [0034]      FIG. 4  shows a tooth of the zipper, according to one embodiment of the present invention. 
           [0035]      FIG. 5  shows a single tooth grasping a tape of the non-waterproof zipper or a tape of the zipper of the present invention yet not waterproof. 
           [0036]      FIG. 6  is a side view of a non-waterproof zipper. 
           [0037]      FIG. 7  shows two teeth grasping a tape of the zipper, according to one embodiment of the present invention. 
           [0038]      FIG. 8  is a side view of a non-waterproof zipper, according to one embodiment of the present invention. 
           [0039]      FIG. 9  is a side view of a first mold for manufacturing a non-waterproof zipper, having plastic teeth. 
           [0040]      FIG. 10  shows steps of manufacturing a non-waterproof zipper, which are also the first steps of manufacturing the waterproof zipper, according to one embodiment of the present invention. 
           [0041]      FIG. 11  is a side view of a second mold for manufacturing the inventive zipper, according to one embodiment of the present invention. 
       
    
    
       [0042]    It should be understood that the drawings are not necessarily drawn to scale. 
       DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
       [0043]    The present invention will be understood from the following detailed description of preferred embodiments, which are meant to be descriptive and not limiting. For the sake of brevity, some well known prior art methods, systems, procedures, components, circuits, and so on, have not been described in detail. 
         [0044]      FIG. 1  is a side view of a zipper according to one embodiment of the present invention. 
         [0045]    A waterproof zipper  2  includes two tapes  4 , fastened one to the other by teeth  6 . Each of tapes  4  and teeth  6  thereof includes a soft seal  8 , such that the two soft seals  8  form together, when tightened one towards the other, a waterproof seal at the fastened zone  10  of waterproof zipper  2 . 
         [0046]    A thermoplastic is a plastic, usually a polymer, which can be remelted and remolded. 
         [0047]    Teeth  6  are made of non-deformable metal or plastic, preferably thermoplastic. 
         [0048]    An elastomer is an elastic and deformable polymer, often named, rubber, primarily used for sealing. 
         [0049]    The material of soft seal  8  may be Thermoplastic Elastomers (TPE), which is a family of polymers, combining the features of thermoplastics and elastomers. 
         [0050]    Thermoplastic Elastomers (TPE) can be repeatedly stretched without permanently deforming the shape of the part. Also, they may be processed by conventional thermoplastic techniques such as injection molding, extrusion and blow molding. 
         [0051]    Examples of TPEs are styrenic block copolymers, polyolefin blends (TPOs), elastomeric alloys, thermoplastic polyurethanes (TPUs), thermoplastic copolyesters and thermoplastic polyamides. 
         [0052]      FIG. 2  is a side view of a non-waterproof zipper. 
         [0053]    A prior art zipper  12  includes two tapes  4 , fastened one to the other by teeth  6 . However, zipper  12  does not include seals  8 . Thus, zipper  12  is not sealed at the fastened zone  10  thereof, and thus is not waterproof. 
         [0054]      FIG. 3  shows a tape of the non-waterproof zipper and of the zipper of the present invention. 
         [0055]    Tape  4  includes a wide thin stripe  16 , for being sewn to a fabric; and a narrow thickened stripe  14  providing a firm basis to each of teeth  6 . 
         [0056]      FIG. 4  shows a tooth of the zipper, according to one embodiment of the present invention. 
         [0057]    Tooth  6  includes at the first side thereof a grasping unit  40 , for grasping tape  4 . Grasping unit  40  includes a groove  20 , which suits the thickness of thin stripe  16 , and a cylindrical recess  18 , having a diameter which suits thickened stripe  14 . 
         [0058]    Tooth  6  includes at the opposite side a joining unit  22 , for joining the joining units of the adjacent teeth  6 . Joining unit  22  is split to an upper reed  26  and to a lower reed  28 , including a slot  30  in between. 
         [0059]    Joining unit  22  includes a wide zone  34  at the edge of tooth  6 , and a narrow zone  36  at the center of tooth  6 . 
         [0060]    Although cylindrical recess  18  and joining unit  22  are split, tooth  6  is consolidated by a consolidating block  24 , consolidating the splits of grasping unit  40  and of joining unit  22  (the holes in consolidating block  24  are not significant). 
         [0061]    Another function of consolidating block  24  is for stabilizing opposite tooth  6 , by inserting consolidating block  24  of one tooth  6  into slot  30  of an opposite tooth  6 . 
         [0062]    Tooth  6  includes a stair  80  in slot  30  between consolidating block  24  and upper reed  26  of joining unit  22 , and another stair  80  between consolidating block  24  and lower reed  28 . Stairs  80  provide that slot  30 , between upper reed  26  and lower reed  28 , will be thicker than consolidating block  24 , such that soft seal  8  (shown in  FIG. 1 ) injected into slot  30  will cover consolidating block  24 . 
         [0063]    Usually, teeth of prior art zippers include all of the above-mentioned components of tooth  6  except for stair  80 . 
         [0064]      FIG. 5  shows a single tooth grasping a tape of the non-waterproof zipper or a tape of the zipper of the present invention yet not waterproof. 
         [0065]    Thickened stripe  14  of tape  4  is inserted into cylindrical recess  18  of tooth  6 , and thin stripe  16  of tape  4  is inserted into groove  20  of tooth  6 . Waterproof zipper  2 , like the non-waterproof zipper, includes the same firm grasping of tooth  6  to tape  4 . 
         [0066]    Thus tooth  6  of waterproof zipper  2  also contactably grasps tape  4 , i.e there is no sealing between tape  4  and tooth  6 . 
         [0067]      FIG. 6  is a side view of a non-waterproof zipper. 
         [0068]    Teeth  6  of non-waterproof zipper  12  are shown joined at the upper zone  10 , presenting the principal of joining the zipper. For example, wide zone  34  of tooth  42  is confined between two narrow zones  36  and wide zones  34  of teeth  44  and  46 . 
         [0069]    Teeth  6  separate between the thick stripes  14  of tapes  4 , thus sealing of tapes  6  does not seal between tapes  4 . 
         [0070]    The mechanical confinement of wide zone  34  of tooth  42  might leave undesired space  38  between wide zone  34  of tooth  42  and grasping units  40  of teeth  44  and  46 . Thus, non-waterproof zipper  12  is not waterproof. 
         [0071]      FIG. 7  shows two teeth grasping a tape of the zipper, according to one embodiment of the present invention. 
         [0072]    Waterproof zipper  2  is similar to non-waterproof zipper  12 , except for an additional soft seal  8 , which may require a slightly different tooth  6 . 
         [0073]    Seal  8  provides sealing of water, such that zipper  2  becomes waterproof. 
         [0074]    Soft seal  8  may provide an additional feature of an advertisement  32  or caption functionality, or other information provision, by injecting the liquid seal in a pre-determined shape. 
         [0075]    According to the present invention, a soft seal  8  wraps thin stripe  16  and thickened stripe  14  of tape  4 . Seal  8  expands thin stripe  16  to penetrate into the internal region of slot  30 , between upper reed  26  and lower reed  28 . 
         [0076]    Since slot  30  is slightly thicker than consolidating block  24  due to stairs  80 , soft seal  8 , injected into slot  30 , also wraps consolidating block  24 . 
         [0077]    Soft seal  8  expands around tooth  6 , crossing from one tooth  6  to another forming a straight border  48 . 
         [0078]      FIG. 8  is a side view of a non-waterproof zipper, according to one embodiment of the present invention. 
         [0079]    Seal  8  forms a continuous layer, starting from tape  4 , and ending at margin  48 . Thus, spaces  38  between wide zone  34  of tooth  42  and grasping units  40  of teeth  44  and  46 , are also filled by seal  8 , as seal  8  expands thin stripe  16 . 
         [0080]    The term “joining line”, denoted by numeral  78 , refers herein to the center line between the two thickened stripes  14  of the two tapes  4 , or the center line between the opposite teeth  44  and  42 . 
         [0081]    The depth of the expansion, which defines border  48  of seal  8  of each tape  4 , is designed to be beyond joining line  78  between tapes  4 . 
         [0082]    Teeth  6  of waterproof zipper  2 , like of non-waterproof zipper  12 , employ, upon closing of zipper  2 , mechanical joining force  82  towards joining line  78 . Since the borders  48  of the two seals  8  expand beyond joining line  78 , they employ pressure one on the other, providing tight sealing on line  78 . Thus zipper  2  is water proof. 
         [0083]    The depth of the expansion of seal  8  beyond joining line  78  may be determined according to sealing considerations, depending on the elastics and other characteristics of the material of seal  8 , and on the characteristics of joining force  82 , produced by the teeth, including teeth  42 ,  44  and  46 . 
         [0084]      FIG. 9  is a side view of a first mold for manufacturing a non-waterproof zipper, having plastic teeth. 
         [0085]    A first mold  50  includes a lower member  52 , an upper member  56  and a mold insert  54  in between, having together a space  60  of the negative shape of a tooth  6  shown in  FIG. 5 . Mold  50  includes a pipe  58  for injecting thermoplastic into space  60 . 
         [0086]      FIG. 10  shows steps of manufacturing a non-waterproof zipper, which are also the first steps of manufacturing the waterproof zipper, according to one embodiment of the present invention. 
         [0087]    At step  1  tape  4 , including wide thin stripe  16  and narrow thickened stripe  14 , is placed on lower member  52  of first mold  50 . It should be noted that for manufacturing waterproof zipper  2 , first mold  50  should fit tooth  6 . 
         [0088]    At step  2  upper member  56  is placed on lower member  52  and on mold insert  54 , forming together space  60  of the negative shape of a tooth  6 . 
         [0089]    Then thermoplastic is injected through pipe  58  into space  60 . 
         [0090]    At step  3  upper member  56  is raised revealing a new tooth  6  grasping to tape  4 . Mold insert  54  is slid aside, revealing slot  30  in tooth  30 . 
         [0091]    One tape of non-waterproof zipper  12 , including tape  4  with a plurality of teeth  6 , is then separated from first mold  50 . 
         [0092]    If in steps  1  to  3 , first mold  50  fitted teeth  6 , then the process may continue to manufacture waterproof zipper  2 . 
         [0093]      FIG. 11  is a side view of a second mold for manufacturing the inventive zipper, according to one embodiment of the present invention. 
         [0094]    A second mold  62  includes a lower member  66 , an upper member  64  and a mold insert  68  in between, forming together a space  70  shaped as the negative shape of a tape of waterproof zipper  2 , as depicted in  FIG. 7 . 
         [0095]    Mold  62  includes also a pipe  72  for injecting Thermoplastic Elastomer (TPE) or another soft seal  8  into space  70 . 
         [0096]    Space  72  of second mold  62  is slightly thicker than space  60  of first mold  50 . For example, stair  88  of first mold  50  hardly exists, since it should contain only half of the thickness of thin stripe  16 , whereas stair  76  of second mold  62  is significantly thicker, since it should also contain, except for the half of the thickness of thin stripe  16 , the thickness of the upper layer of soft seal  8 . 
         [0097]    Upper mold  64  may include a stamp  32 , for producing a shape or another caption on tape  4  or between teeth  6 , for advertising or another purpose. 
         [0098]      FIG. 12  shows the steps of using the second mold of  FIG. 10 , according to one embodiment of the present invention. 
         [0099]    The steps of using second mold  62  are performed after the steps of using first mold  50 , thus the steps of using second mold  62  are referred as starting from step no.  4 . 
         [0100]    At step  4  non-waterproof zipper  12  tape  4 , including wide thin stripe  16 , narrow thickened stripe  14 , and prior art teeth  6  are inserted in space  70  on lower member  66  of second mold  62 . Wide thin stripe  16  is raised by pins  74  of lower member  66  of second mold  62 , such that TPE can penetrate below wide thin stripe  16 , between pins  74 . 
         [0101]    Mold insert  68  of second mold  62  is inserted into slot  30 , as deep as margin  48 , thus leaving space for the soft seal to penetrate. 
         [0102]    At step  5  upper member  64  is placed on lower member  66  and on mold insert  68 . The space left includes a thin space  70  below wide thin stripe  16 , a thin space  72  above wide thin stripe  16 , the space left in slot  30  by mold insert  68 , and the other areas depicted in  FIGS. 7 and 1 . 
         [0103]    Then TPE or another liquid seal  84  is injected through pipe  86  into spaces  70 ,  72 ,  74 , and the other areas depicted in  FIGS. 7 and 1 . 
         [0104]    At step  6 , after liquid seal  84  solidifies, becoming soft seal  8 , upper member  64  is raised and mold insert  68  is slid aside, revealing one tape of waterproof zipper  2 . 
         [0105]    According to manufacturing steps  1  to  6 , it may be appreciated that waterproof zipper  2  includes the mechanical advantaged features of non-waterproof zipper  12 . 
         [0106]    Waterproof zipper  2 , like non-waterproof zipper  12 , includes the firm grasping of tooth  6  to tape  4 , provided by injecting seal  8  (steps  4 , 5 , 6 ) after the manufacturing of teeth  6  (at steps  1 , 2 , 3 ). 
         [0107]    Waterproof zipper  2 , like non-waterproof zipper  12 , also includes the stabilization between adjacent and opposite teeth  6 , provided by sufficient thin seal  8 , injected at the regions of consolidating block  24 , which, like in the non-waterproof zipper, stabilize the adjacent and opposite tooth  6  together. 
         [0108]    In the figures and description herein, the following reference numerals and symbols have been mentioned:
       numeral  2  denotes a waterproof zipper according to one embodiment of the present invention;   numeral  4  denotes a tape of a zipper;   numeral  6  denotes a tooth of the waterproof zipper;   numeral  8  denotes a soft seal;   numeral  10  denotes the fastened zone of a zipper;   numeral  12  denotes a non-waterproof zipper, which may include the prior art zipper of the zipper of the present invention prior to adding the soft seal;   numeral  14  denotes the narrow thickened stripe  14  of the tape of a zipper, also named “cordell”;   numeral  16  denotes the wide thin stripe of the tape of a zipper, which is sewn to a fabric;   numeral  18  denotes a cylindrical recess in the tooth;   numeral  20  denotes a groove in the tooth;   numeral  22  denotes the joining unit of a tooth;   numeral  24  denotes the consolidating block of the tooth;   numeral  26  denotes the upper reed of the slot of the tooth;   numeral  28  denotes the lower reed of the slot of the tooth;   numeral  30  denotes the slot of the tooth;   numeral  32  denotes a stamp or a caption on the soft seal;   numeral  34  denotes the wide zone of the joining unit of the tooth;   numeral  36  denotes the narrow zone of the joining unit of the tooth;   numeral  38  denotes an undesired space between teeth, through which water can penetrate, unless having a waterproof seal;   numeral  40  denotes the grasping unit of the tooth;   numerals  42 ,  44  and  46  denote certain teeth;   numeral  48  denotes the border of the soft seal;   numeral  50  denotes a first mold, for producing teeth on a tape;   numeral  52  denotes a lower member of the first mold;   numeral  54  denotes a mold insert of the first mold;   numeral  56  denotes an upper member of the first member;   numeral  58  denotes a pipe for injecting the thermoplastic for producing the tooth;   numeral  60  denotes a space in the first mold;   numeral  62  denotes a second mold;   numeral  64  denotes an upper member of the second mold;   numeral  66  denotes a lower member of the second mold;   numeral  68  denotes a mold insert of the second mold;   numeral  70  denotes the space formed by the second mold;   numeral  72  denotes a pipe for injecting the soft seal;   numeral  74  denotes pins in the second mold for raising the tape in the second mold;   numeral  76  denotes a stair in the second mold;   numeral  78 , named “joining line”, denotes the center line between the tapes;   numeral  80  denotes a stair in the slot of the tooth;   numeral  82  denotes mechanical force, employed by the teeth towards the center of the zipper, by being joined;   numeral  84  denotes a liquid seal, which becomes the soft seal after solidifying;   numeral  86  denotes a pipe of the second mold; and   numeral  88  denotes a stair in the first mold.       
 
         [0151]    The foregoing description and illustrations of the embodiments of the invention has been presented for the purposes of illustration. It is not intended to be exhaustive or to limit the invention to the description above in any form.

Technology Category: y