BACKGROUND OF THE INVENTION

Field of Invention

[0001] This invention relates to slide fasteners and, in particular, to concealed weather-resistant curvable slide fasteners and to methods of manufacturing slide fasteners of this type.

Description of Related Art

[0002] Fasteners, such as conventional slide fasteners or zippers, are often used for joining textile material or fabric along two parallel longitudinal edges that define a longitudinal gap or opening in an article, such as a garment, bag or technical outdoor gear.

[0003] Conventional slide fasteners include fastening or coupling elements, such as coils or rows of teeth, installed on mounting tapes which are in turn mounted on the fabric of the article along the longitudinal edges of an opening. A mounting tape having coupling elements installed on a surface thereof may be referred to as a stringer. The coupling elements may for example be made of metal or plastic, and may be installed on a mounting tape by stitching, molding or casting the coupling elements to the mounting tape, for example. After the coupling elements are installed, the stringer may be installed on the article, for example by stitching, gluing, fusion bonding or ultrasonic welding to the fabric of the article.

[0004] The stringer of a conventional slide fastener typically binds when bent or curved in the plane of the fabric upon which the stringer is installed. Consequently, slide fasteners employing stringers are generally limited to relatively large radii of curvature, or more often no curvature at all, in the plane of the fabric. In commercial applications, the selection of mounting tapes may not be amenable to colour matching between the slide fastener and the article. [0005] In many outdoor garments, the fabric of the article or the material of a mounting tape may form a flap that covers the longitudinal opening to make the opening water-resistant or weather-resistant (i.e. resistant to the penetration of fluids, including water and air, for example) upon closure of the slide fastener. The flap may be permanently attached along one longitudinal edge and removably attachable at its other longitudinal edge. The other longitudinal edge may provide a weather-resistant seal displaced from the longitudinal opening. Such flaps, however, require additional material that may increase bulkiness and manufacturing costs and may not be colour matched nor aesthetically pleasing, and may require the user to perform additional steps in fastening and unfastening. Providing a weather-resistant seal displaced from the longitudinal opening may reduce the weather-resistance of the slide fastener by permitting fluid to pass between the seal and the opening.

[0006] The coupling elements of some conventional slide fasteners are exposed to ultraviolet radiation in sunlight, which may reduce the durability and useful lifetime of the slide fastener. Some conventional slide fasteners that hide or make invisible their coupling elements by covering them with a cover do not place or maintain such cover in a weather-resisting position and thus do not provide a weather-resistant seal.

SUMMARY

[0007] In accordance with one aspect, the invention provides a slide fastener. The slide fastener may include first and second opposing edgings formed in an article adjacent an opening, the edgings comprising first and second outer layers and first and second inner layers. The inner and outer layers may be integrally connected, and may be adhered to the outer layers, to form first and second opposing folds connecting the inner and outer layers, respectively. A pair of interlocking trains of fastening elements may be mounted directly onto inner surfaces of the inner layers and spaced apart from the opening. A slider slidable may be provided that rides on the interlocking trains and on outer surfaces of the outer layers, to cause the trains to interlock and the folds to mutually abut. The folds may abut along complementarity curved edges when the trains interlock. Each train may be stitched to a corresponding one of the inner layers only, so that the stitching does not penetrate the outer layers. The inner layers may for example be adhered to the outer layers, and the adhesive may for example be a heat curable adhesive. The outer layer may for example be made of breathable, water-resistant material. Each train may for example be a fastening coil, and the fastening elements may be fastening teeth.

[0008] In accordance with another aspect of the invention, there is provided a method of manufacturing a slide fastener. The method may involve mounting a pair of interlocking trains of fastening elements directly onto an article. The article may be folded to form first and second opposing folds and first and second opposing edgings The edgings may comprise first and second outer layers and first and second inner layers and the inner and outer layers may be integrally connected. The edgings may be adjacent to an opening in the article, and the trains may be mounted onto inner surfaces of the inner layers, respectively. The inner layers may be adhered to the outer layers, such that the trains are spaced apart from the opening. A slider may be installed that is slidable, by riding on the interlocking trains and on outer surfaces of the outer layers, to cause the trains to interlock and the folds to mutually abut. Folding the article may involve folding the article along curved edges. The step of mounting may involve stitching each train to one of the inner layers only, so that the stitching does not penetrate the outer layers. The step of adhering may be preceded by the step of mounting. The method may involve applying to the article heat curable adhesive for adhering the outer layers to the inner layers. The step of adhering may involve using the slider to fasten the opening; and curing the adhesive while the opening is fastened. Curing the adhesive may involve placing the article on a heat block operable to receive the article at the inner side of the article; and heating the article from the outer side of the article. The step of mounting may comprise mounting a pair of interlocking fastening coilsor mounting a pair of interlocking trains of fastening teeth. [0009] In accordance with another aspect of the invention, there is provided a method of manufacturing a slide fastener. The method may include the step of mounting a pair of interlocking trains of fastening elements directly onto an article. First and second outer layers of first and second opposing edgings formed in the article adjacent an opening of the article may be attached to first and second inner surfaces of inner layers of the edgings, respectively, such that the trains are spaced apart from the opening. A slider may be installed so that it is slidable, by riding on the interlocking trains and on outer surfaces of the outer layers, to cause the trains to interlock and the edgings to mutually abut. The step of attaching may involve attaching first and second outer layers made of breathable, water-resistant material. Attaching first and second outer layers may involve attaching first and second water-resistant seam tapes.

[0010] In accordance with another aspect of the invention, there is provided an apparatus for fastening an opening in an article. The apparatus may include a pair of interlocking means for interlocking; first and second support means for supporting the interlocking means, the first and second support means being formed in the article adjacent the opening and comprising first and second outer layers and first and second inner layers integrally connected and adhered to the outer layers to form first and second opposing folds, respectively; and abutting means for causing the trains to interlock and the folds to mutually abut by riding on the interlocking means and on outer surfaces of the outer layers. The interlocking means may be mounted directly onto inner surfaces of the inner layers and spaced apart from the opening.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] In drawings which illustrate embodiments of the invention,

Figure 1 is an isometric view depicting a slide fastener for fastening an opening in an article according to a first embodiment of the invention; Figure 2 is an isometric view depicting a slider, prior to being installed, of the slide fastener shown in Figure 1; Figure 3 is an isometric view depicting a fastening coil mounted to the article shown in Figure 1 , showing a fold that is partly folded; Figure 4 is an isometric view depicting a second embodiment of the slide fastener shown in Figure 1 , showing outwardly folded edge portions; Figure 5 is an isometric view depicting a third embodiment of the slide fastener shown in Figure 1 , showing edge portions including outer and inner layers that are not integrally connected; Figure 6 is an isometric view depicting adhesive applied to the article shown in Figure 1 ; Figure 7 is an isometric view depicting fastening coils being stitched to the article shown in Figure 1 ; and Figure 8 is an isometric view depicting heat curing the adhesive shown in Figure 6.

DETAILED DESCRIPTION

[0012] Referring to Figure 1, an apparatus, which may be referred to as a slide fastener, according to a first embodiment of the invention is shown generally at 10. The slide fastener 10 operates to fasten and unfasten an opening 12 in an article 14, which may for example be a garment, bag or technical outdoor gear. The article 14 is typically made of a textile material or fabric, and may be made of a breathable material or a waterproof, water- resistant or weather-resistant material. The article 14 has an outer side 16 and an inner side 18 opposite the outer side 16.

[0013] The opening 12 is defined between edges 20 and 22. The edges 20 and 22 are in opposing, parallel relation to each other and may be straight, curved, or contain straight and curved sections. The ends (not shown) of the edges 20 and 22 may respectively coincide on the article 14 so that the edges 20 and 22 together completely circumscribe the opening 12, or the edges 20 and 22 may be separable when the opening 12 is unfastened. [0014] The article 14 includes edgings such as the double-layered edge portions 24 and 26. The edge portions 24 and 26 include the edges 20 and 22, outer layers 28 and 30 and inner layers 32 and 34, respectively. The outer layers 28 and 30 are attached to the inner layers 32 and 34 along the contact surface areas 31 and 33, respectively. The outer layers 28 and 30 may be adhered to the inner layers 32 and 34, respectively, by heat curable adhesive, for example. The edge portions 24 and 26 of the first embodiment extend from the edges 20 and 22 in opposing directions along the outer layers 28 and 30 and along the inner layers 32 and 34 to extents defined by terminating edges of the inner layers 32 and 34, respectively. The outer layers 28 and 30 are typically made of breathable, water-resistant material, as may also be the inner layers 32 and 34. The outer layers 28 and 30 may each be made of several sub-layers (not shown), provided that their respective outer surfaces 36 and 38 face the outer side 16 of the article 14. Similarly, the inner layers 32 and 34 may each be made of several sub-layers (not shown), provided that their respective inner surfaces 40 and 42 face the inner side 18 of the article 14.

[0015] As shown in Figure 1 , the slide fastener 10 includes a pair of opposing and interlocking sets of fastening elements, which may be rows of fastening teeth or the fastening coils 44 and 46, for example. By the operation of the slide fastener 10, each fastening loop 48 of the fastening coils 44 and 46 interlocks between a corresponding pair of fastening loops 48 of the opposing fastening coil and is subsequently released from such interlocking. The fastening coil 44 is mounted directly onto the inner surface 40 of the inner layer 32 along, but not precisely at, the edge 20. Similarly, fastening coil 46 is mounted directly onto the inner surface 42 of the inner layer 34 along, but not precisely at, the edge 22. The fastening coils 44 and 46 may be mounted by stitching, gluing, fusion bonding or ultrasonic welding, for example. The fastening coils 44 and 46 may be stitched to the inner layers 32 and 34 such that the outer layers 28 and 30 remain free of stitching. Not stitching the outer layers 28 and 30 effectively preserves the weather- resisting characteristics of the outer layers 28 and 30 without the need to cover any stitching by, for example, the use of water-resistant tape. Mounting the fastening coils 44 and 46 displaced from the edges 20 and 22 permits the edge portions 24 and 26 to conceal the fastening coils 44 and 46 such that they are not visible from the outer side 16. Concealing the fastening coils 44 and 46 minimizes exposure of the fastening loops 48 to sunlight and ultraviolet radiation, which may increase the durability and useful lifetime of the slide fastener 10. Mounting the fastening coils 44 and 46 directly to the article 14 permits the edges 20 and 22, or portions thereof, to have small radii of curvature unrestricted by, for example, a mounting tape of a stringer. A small radius of curvature along any portion of the edges 20 and 22 may necessitate the use of correspondingly small fastening loops 48.

[0016] Thus, the first embodiment provides a pair of interlocking trains of fastening elements mounted directly onto inner surfaces of the inner layers and spaced apart from the opening. Such pair provides a pair of interlocking means for interlocking whereby the interlocking means are mounted directly onto inner surfaces of the inner layers and spaced apart from the opening.

[0017] As shown in Figure 1 , the slide fastener 10 includes a slider 50 that is of appropriate size and design to contact and move along the opposing fastening coils 44 and 46 in order to releasably interlock the opposing fastening coils 44 and 46. Figure 1 shows an open portion 52 of the opening 12 where corresponding fastening loops 48 are released and a closed portion 54 of the opening 12 where corresponding fastening loops 48 are interlocked. Figure 1 shows by an arrow 56 pointed away from the slider 50 the direction in which the slider 50 must be moved in order to cause corresponding fastening loops 48 to become interlocked. Moving the slider 50 in a direction opposite to the direction shown by the arrow 56 causes interlocked fastening loops 48 to be released.

[0018] Referring to Figures 1 and 2, the slider 50 includes outer flanges 58 extending in opposing directions from the slider 50 on the outer side 16 of the article 14 respectively adjacent the outer surfaces 36 and 38 to make contact with and run along the outer surfaces 36 and 38. The slider 50 also includes inner flanges 60 that extend in opposing directions from the slider 50 to respectively make contact with and run along the fastening coils 44 and 46. The flanges 58 and 60, in conjunction with other parts of the slider 50, interlock and release the fastening coils 44 and 46 by straddling the edges 20 and 22, respectively.

[0019] The respective portions of the edges 20 and 22 along the closed portion 54 are forced by the interlocking operation of the slider 50 toward each other into a mutually abutting relation that minimizes or closes any gap between the edges 20 and 22. The directions of the forces exerted to create and maintain this abutting relation is depicted in Figure 1 by a pair of mutually facing arrows 62. The forces exerted on the edges 20 and 22 along the closed portion 54 depend at least in part on the material of the article 14 and the respective distances to which the fastening coils 44 and 46 are displaced from the edges 20 and 22. Appropriately located, the interlocked fastening loops 48 along the closed portion 54 maintain the edges 20 and 22 in the mutually abutting relation, thereby resulting in a weather-resistant seal at the closed portion 54. The fastening loops 48 may exert sufficient forces to bring the edges 20 and 22 into forceful abutment, thereby increasing the effectiveness of the weather-resistant seal. During operation of the slide fastener 10, the outer flanges 58 ride along the outer surfaces 36 and 38 to resist any tendency for the edge portions 24 and 26 to curl over time outerwardly and away from each other, which might create an undesirable gap between the edges 20 and 22 along the closed portion 54. The outer flanges 58 assist to maintain, even after repeated use of the slide fastener 10, the edge portions 24 and 26 coplanar such that the edges 20 and 22 along the closed portion 54 mutually abut to form a weather-resistant seal.

[0020] Thus, the first embodiment provides a slider slidable, by riding on the interlocking trains and on outer surfaces of the outer layers, to cause the trains to interlock and the edgings to mutually abut.

[0021] Referring to Figures 2 and 3, the outer and inner layers 28 and 32 and the outer and inner layers 30 and 34 of the first embodiment are integrally connected to form the inward folds 66 and 68 defined by the edge portions 24 and 26, respectively. The inwardly folded edges 70 and 72 of the folds 66 and 68 coincide with the edges 20 and 22 (Figure 1), respectively, and thus are in opposing, parallel relation to each other and may be straight, curved, or contain straight and curved sections. The fastening coils 44 and 46 of the first embodiment are mounted in such locations on the article 14 that the fastening coils 44 and 46 become directly mounted to inner surfaces 40 and 42 of the inner layers 32 and 34 after the folds 66 and 68 have been created by inwardly folding the article 14, respectively. As shown in Figure 1, the folds 66 and 68 will mutually abut along the complementarily straight and curved portions of the edges 20 and 22 when the opening 12 is fastened.

[0022] Thus, the first embodiment provides first and second opposing edgings formed in the article adjacent the opening, the edgings comprising first and second outer layers and first and second inner layers integrally connected and adhered to the outer layers to form first and second opposing folds, respectively, and provides a slider slidable, by riding on the interlocking trains and on outer surfaces of the outer layers, to cause the trains to interlock and the folds to mutually abut. The first embodiment further provides first and second support means for supporting interlocking means, the first and second support means being formed in the article adjacent the opening and comprising first and second outer layers and first and second inner layers integrally connected and adhered to the outer layers to form first and second opposing folds, respectively. The first embodiment further provides abutting means for causing the trains to interlock and the folds to mutually abut by riding on the interlocking means and on outer surfaces of the outer layers.

[0023] A second embodiment shown in Figure 4 is similar to the first embodiment described above, but the folds 74 and 76 are outwardly folded and have outwardly folded edges 78 and 80 coincident with the edges 20 and 22, respectively. As with the first embodiment, the fastening coils 44 and 46 of the second embodiment are mounted, such as by stitching, in such locations on the article 14 that the fastening coils 44 and 46 become directly mounted to the inner surfaces 40 and 42 of the inner layers 32 and 34 after the folds 74 and 76 have been created by outwardly folding the article 14, respectively. As shown in Figure 4, the outward folds 74 and 76 mutually abut along the complementarily straight and curved portions of the edges 20 and 22 when the opening 12 is fastened. As with the first embodiment, the outer layers 28 and 30 are typically made of breathable, water-resistant material, as may also be the inner layers 32 and 34, and the outer layers 28 and 30 may be free of stitching.

[0024] The third embodiment shown in Figure 5 is similar to the first and second embodiments described above, but the outer and inner layers 28 and 32 and the outer and inner layers 30 and 34 are not integrally connected and do not form any folds having folded edges coincident with the edges 20 and 22. The fastening coils 44 and 46 of the third embodiment are mounted, such as by stitching, directly onto the inner surfaces 40 and 42 of the inner layers 32 and 34 of the edge portions 24 and 26, respectively. As with the first and second embodiments, the outer layers 28 and 30 may be free of stitching. The outer layers 28 and 30 may be made of breathable, water- resistant material; alternatively or additionally, the outer layers 28 and 30 may include water-resistant seam tape. Fraying along the edges 20 and 22 may be prevented by the use of edge-stable material for the outer and inner layers 28, 30, 32, and 34, and/or by applying a suitable coating to the edges 20 and 22, for example.

Manufacturing Process

[0025] In accordance with an alternative aspect of the invention, a process of manufacturing the slide fastener 10 is provided.

[0026] Referring to Figure 6, an adhesive for adhering the outer layers 28 and 30 to the inner layers 32 and 34, respectively, may be applied to the article 14. The adhesive may be in the form of adhesive strips 82, each strip 82 having a paper backing on one side. Each adhesive strips 82 may be applied to the article 14 by laminating the side of the adhesive strip 82 opposite the paper-backed side using a process of applying pressure and heat, for example.

[0027] Referring to Figure 7, the fastening coils 44 and 46 may be directly mounted to the article 14 by, for example, sewing, which may include stitching the fastening coils 44 and 46 directly to the material of the article 14 using sewing machine heads 64. Each fastening loop 48 may be separately stitched to the material of the article 14, for example. The fastening coils 44 and 46 may be mounted before or after the adhesive strips 82 are laminated. Alternatively, fastening teeth (not shown) may be attached to the article 14.

[0028] Referring back to Figure 3, when the fastening coil 44 has been mounted and the adhesive strip 82 has been laminated to all or a portion of the contact surface area 31 , the paper backing of that adhesive strip 82 may be removed and the article 14 folded in the inward direction indicated by the arrows 84 until contact between the outer layer 28 and the inner layer 32 is made along the contact surface area 31. In this way, the inner layer 32 has been placed inwardly adjacent to the outer layer 28 so as to form the fold 66 having the inwardly folded edge 70 coincident with edge 20. Folding may occur along straight or curved edges or sections thereof. The outer and inner layers 28 and 32 may be adhesively attached by applying adhesive to the entire contact surface area 31 or a portion thereof. This procedure of attaching the inner layer 32 to the outer layer 28 produces the edge portion 24 (Figures 1 and 2), with the outer layer 28 and the inner layer 32 being integrally connected and with the fastening coil 44 being substantially alongside and displaced from the edge 20. The edge portion 26 may be produced by a correspondingly similar procedure.

[0029] The fastening coils 44 and 46 may be stitched to the inner layers 32 and 34 only, with the outer layers 28 and 30 remaining free of stitching, to preserve the weather-resisting characteristics of the outer layers 28 and 30 without the need to cover any stitching by, for example, the use of water- resistant tape. [0030] Referring back to Figure 2, after the edge portions 24 and 26 have been produced and the fastening coils 44 and 46 mounted, the slider 50 may be installed. Installing the slider 50 may include inserting respective ends of the fastening coils 44 and 46 into respective receiving portions 86 and 88 of the slider 50, as shown generally by the arrows 90.

[0031] Thus, the slide fastener 10 of the first embodiment may be manufactured by a method that involves mounting a pair of interlocking trains of fastening elements directly onto an article; folding the article to form first and second opposing folds and first and second opposing edgings, the edgings comprising first and second outer layers and first and second inner layers integrally connected to the outer layers, such that the edgings are adjacent an opening of the article and the trains are mounted onto inner surfaces of the inner layers, respectively; adhering the inner layers to the outer layers such that the trains are spaced apart from the opening; and installing a slider slidable, by riding on the interlocking trains and on outer surfaces of the outer layers, to cause the trains to interlock and the folds to mutually abut.

[0032] Referring to Figure 8, heat curing the adhesive strips 82 may reduce the amount of time required for curing and may also enhance the resulting adhesion of the adhesive strips 82. One may prepare the slide fastener 10 for heat curing by installing the slider 50, using the slide fastener 10 with the slider 50 installed to completely fasten the opening 12 and then removing the slider 50 from the article 14 while maintaining the opening 12 completely fastened. Preparing the slide fastener in such manner facilitates handling of the article 14 during the curing process and may improve the uniformity and reliability of the adhesion of adhesive strips 82. After the slide fastener 10 has been prepared, heat curing may involve supporting the article 14 on a heat block 92 and applying heat to the outer side 16 of the article 14, as indicated by the arrows 94 shown in Figure 8. The heat block 92 may include a longitudinal recess of appropriate dimensions for receiving the article 14 at its inner side 18 with the fastening coils 44 and 46 mounted. Heat may be applied for an amount of time dependent on known properties of the adhesive strips 82. Finally, the heat may be removed and the article 14 allowed to cool to an ambient temperature.

[0033] When the adhesive strips 82 have fully cured, final installation of the slider 50 may then occur in a manner similar to that described above with reference to Figure 2. The slider 50 may then be used to fasten and unfasten the opening 12. Slide fastener ends (not shown) may be created, such as by sewing, in the article 14 to restrict the extent to which the slider 50 may be moved in and against the direction indicated by the arrow 56 (Figure 1).

[0034] The second and third embodiments are manufactured similarly to the above-described process in that the method for manufacturing the slide fastener 10 in accordance with all three embodiments described herein involves mounting a pair of interlocking trains of fastening elements directly onto an article; attaching first and second outer layers of first and second opposing edgings formed in the article adjacent an opening of the article to first and second inner surfaces of inner layers of the edgings, respectively, such that the trains are spaced apart from the opening; and installing a slider slidable, by riding on the interlocking trains and on outer surfaces of the outer layers, to cause the trains to interlock and the edgings to mutually abut.

[0035] In the case of the second embodiment, the fastening coils 44 and 46 and the adhesive strips 82 are directly mounted in locations determinable from Figure 4 such that outwardly folding the article 14 places the fastening coils 44 and 46 on the inner surfaces 40 and 42 of the inner layers 32 and 34, respectively. As with the first embodiment, attaching the outer layers 28 and 30 may involve attaching such outer layers 28 and 30 made of breathable, water-resistant material.

[0036] In the case of the third embodiment shown in Figure 5, the outer layers 28 and 30 may be adhesively attached to the inner layers 32 and 34 by attaching breathable, water-resistant material and/or water-resistant seam tape along the contact surface areas 31 and 33. The edges 20 and 22 may be inherently edge-stable; additionally or alternatively, the edges 20 and 22 may be coated to enhance edge stability.

[0037] While specific embodiments of the invention have been described and illustrated, such embodiments should be considered illustrative of the invention only and not as limiting the invention as construed in accordance with the accompanying claims.