Zipper construction

Abstract

A zipper construction includes first and second fabric pieces. Each of the first and second fabric pieces includes an inner edge to which teeth are affixed. The first and second fabric pieces are formed of a weave defined by pre-dyed warp fibers formed of a substantially inelastic material and weft fibers that are formed of an elastic material. The zipper construction also includes a slider that engages the teeth of the first and second fabric pieces.

1 . A zipper construction comprising:
 first and second fabric pieces, wherein each of the first and second fabric pieces includes a first region to which teeth are affixed and a second region that is adjacent the first region, the first region being formed of a substantially inelastic material and the second region is formed of an elastic material, wherein each of the first and second pieces is constructed so that there is a seamless transition from the first region to the second region and the fabric piece is elastic in a transverse direction relative to a length of the fabric piece; and   a slider that engages the teeth of the first and second fabric pieces.   
   
   
       2 . The zipper construction of  claim 1 , wherein the first region is formed of a substantially inelastic material selected from the group consisting of cotton, nylon, polyester, and blends thereof. 
   
   
       3 . The zipper construction of  claim 1 , wherein the second region is formed of a blend of fibers including elastic fibers. 
   
   
       4 . The zipper construction of  claim 3 , wherein the blend is selected from the group consisting of cotton and spandex; nylon and spandex; and cotton, nylon and spandex. 
   
   
       5 . The zipper construction of  claim 1 , wherein the first region has a first weave pattern and the second region has a second weave pattern. 
   
   
       6 . The zipper construction of  claim 5 , wherein the first weave is inelastic in the transverse direction, while the second weave is elastic in the transverse direction. 
   
   
       7 . The zipper construction of  claim 1 , wherein the first and second regions are integral with one another. 
   
   
       8 . The zipper construction of  claim 3 , wherein the blend includes between 25% and 50% by weight of the elastic fibers. 
   
   
       9 . A zipper construction comprising:
 first and second fabric pieces, wherein each of the first and second fabric pieces includes an inner edge to which teeth are affixed, the first and second fabric pieces being a woven fabric defined by pre-dyed warp fibers formed of a substantially inelastic material and weft fibers that are formed of an elastic material; and   a slider that engages the teeth of the first and second fabric pieces.   
   
   
       10 . The zipper construction of  claim 9 , wherein the warp fibers comprise pre-dyed polyester fibers and the weft fibers comprise spandex fibers. 
   
   
       11 . The zipper construction of  claim 9 , wherein a stretch ratio as measured by a width of one fabric piece in a relaxed state and a width of the one fabric piece in a stretched state is at least 1:1.85. 
   
   
       12 . The zipper construction of  claim 9 , wherein each fabric piece is formed of at least 20% elastic weft fibers. 
   
   
       13 . The zipper construction of  claim 9 , wherein each fabric piece is formed of at least 25% elastic weft fibers. 
   
   
       14 . The zipper construction of  claim 9 , wherein each fabric piece has an outer edge that defines one edge of an attachment zone that represents a portion of the fabric piece that is covered with an object to which the fabric piece is attached, the attachment zone having a width between about 40 to 60% relative to a total width of the tape in it relaxed state. 
   
   
       15 . The zipper construction of  claim 9 , wherein the substantially inelastic fibers are dyed at elevated temperatures that would degrade the elasticity of the inelastic weft fibers. 
   
   
       16 . A method for manufacturing a zipper construction comprising the steps of:
 pre-dyeing warp fibers that are formed of a substantially inelastic material;   introducing the pre-dyed warp fibers into a fabrics loom;   introducing elastic weft into the fabrics loom under substantially constant weft tension;   weaving the warp and weft fibers into a colored zipper tape such that the zipper tape includes at least 20% of the elastic weft, the zipper tape having increased stretch in a transverse direction due to the elastic weft being removed from the pre-dyeing step;   attaching teeth along an inner edge of the zipper tape; and   aligning two pieces of zipper tape with their inner edges facing one another and engaging a slider with the teeth.   
   
   
       17 . The method of  claim 16 , wherein the substantially inelastic fibers comprise polyester fibers that are dyed at elevated temperatures that would otherwise damage the inelastic weft fibers.