BACKGROUND OF THE INVENTION
1. Field of the Invention
[0001] The present invention relates to a fastener stringer which is a material of a slide
fastener, the slide fastener in which fastener elements are molded in a fastener tape
including gaps formed at a portion of the slide fastener on which the fastener elements
are to be mounted, and relates to a method of manufacturing the fastener stringer.
2. Description of the Related Art
[0002] Conventionally, a slide fastener, in which through holes are provided along a side
edge of a fastener tape and fastener elements of thermoplastic resin are attached
to the through holes by injection molding, has been well known. For example, in a
slide fastener shown in FIG. 10 (Japanese Utility Model Application Publication No.
61-35049), a fastener tape 1' is woven by using polyester fiber yarns or union yarns
of polyester fibers and natural fibers as warp yarns 2' and weft yarns 3', through
holes 20' are drilled at predetermined positions of the fastener tape 1' at an equal
interval by ultrasonic wave process, the inner peripheral face of each of the through
holes 20' is formed as a fusion solidified face 27' , fastener elements 13' of polyamide
resin are formed in the through holes 20' by injection molding process, and upper
and lower legs 15' of the fastener elements 13' are connected through the through
holes 20'.
[0003] In the slide fastener shown in FIG. 10, the fastener elements 13' of thermoplastic
resin are mounted on the fastener tape 1' by injection molding, and its procedure
and process are complicated and take a long time and are much troublesome. For example,
a synthetic fiber yarn needs to be used for the fastener tape 1'. Further, a special
unit is required for drilling the through holes 20', so that it takes a long time
for fusing and solidifying, and positioning needs to be carried out accurately when
injection molding the fastener elements 13'.
SUMMARY OF THE INVENTION
[0004] The present invention has been achieved in consideration of the above-described problems.
A first aspect of the invention does not always require using a synthetic fiber yarn
as a yarn to be used in a fastener tape but permits use of a cotton yarn. A main object
of the first aspect of the invention is to provide a slide fastener stringer, in which
a void portion, i.e., a rough warp yarn exclusion area wherein only weft yarns are
left by removing warp yarns in a predetermined width is formed, the warp yarn exclusion
area being formed inside over a certain distance from a side edge of the fastener
tape, and fastener elements of thermoplastic resin or metal such as zinc alloy are
molded in the warp yarn exclusion area.
[0005] In addition to the object of the first aspect, an object of second to fifth aspects
of the invention is to provide a slide fastener stringer in which the fastener elements
of thermoplastic resin or metal such as zinc alloy are mounted on the fastener tape
firmly with a good appearance by molding process.
[0006] An object of a sixth aspect of the invention is to provide a method of manufacturing
the slide fastener stringer, comprising: a weaving step of weaving a water soluble
fiber yarn as a warp yarn into a position along a side edge of the fastener tape;
a heat set step of heat treating the woven tape for a stability of a configuration;
a dying step of dying the fastener tape while dissolving the water soluble fiber yarn
to form a warp yarn exclusion area; and a molding step of molding fastener elements
of thermoplastic resin or metal such as zinc alloy in the warp yarn exclusion area.
[0007] In order to achieve the above-mentioned object, according to the first aspect of
the invention, there is provided slide fastener stringer, wherein a warp yarn exclusion
area deprived of warp yarns is provided inside over plural pieces of the warp yarns
from a side edge of a fastener tape, and fastener elements of thermoplastic resin
or metal such as zinc alloy are formed in the warp yarn exclusion area.
[0008] Consequently, the fastener stringer which is the material of the slide fastener can
be produced easily. Further, the fastener elements can be mounted on the fastener
tape firmly so as to finish an excellent fastener stringer.
[0009] According to the second aspect of the invention, there is provided the slide fastener
stringer, wherein a core thread is disposed between the side edge of the fastener
tape and the warp yarn exclusion area deprived of the warp yarns.
[0010] Consequently, the fastener elements of thermoplastic resin or metal such as zinc
alloy can be molded and fixed to the side edge of the fastener tape firmly.
[0011] According to the third aspect of the invention, there is provided the slide fastener
stringer, wherein at least one warp yarn is interposed between the core thread for
fixing the fastener elements and the warp yarn exclusion area deprived of the warp
yarns.
[0012] Consequently, the core thread disposed on the side edge of the fastener tape can
be maintained in a stable state without inducing any deviation of stitch, so that
the fastener elements of thermoplastic resin or metal such as zinc alloy can be molded
accurately so as to finish a fastener stringer having a high strength.
[0013] According to the fourth aspect of the invention, there is provided the slide fastener
stringer, wherein each of the fastener elements formed by molding thermoplastic resin
or metal such as zinc alloy is formed integrally with a coupling head and a leg, the
coupling head is disposed outside the side edge of the fastener tape, and the leg
is provided through front and rear surfaces of the warp yarn exclusion area.
[0014] With the above feature, the coupling head and the leg of the fastener element are
integral and the coupling head is located accurately outside the fastener tape. As
a consequence, the leg is molded in the warp yarn exclusion area deprived of the warp
yarns such that it penetrates through the front and rear surfaces of the fastener
tape and thus, the leg can be held securely.
[0015] According to the fifth aspect of the invention, there is provided the slide fastener
stringer, wherein the leg of each of the fastener elements strides over a weft yarn
left in the warp yarn exclusion area on both front and rear surfaces thereof, and
a front end portion of the leg is bonded to a warp yarn existing inside the fastener
tape.
[0016] Consequently, the leg of the fastener element is closely-attached to the weft yarns
arranged neatly and the front end of the leg is closely-attached to the warp yarn
facing the exclusion area, thereby preventing the leg from moving. As a consequence,
a solid fastener stringer can be finished.
[0017] According to the sixth aspect of the invention, there is provided a method of manufacturing
a slide fastener stringer, comprising: a weaving step of disposing plural pieces of
warp yarns formed from water soluble fiber yarns, for example, water soluble vinylon,
as the warp yarns at an inside position from a side edge of a fastener tape having
a predetermined width and weaving with the warp yarns; a heat set step of heat treating
the fastener tape; a dying step of dying the fastener tape while dissolving the water
soluble fiber yarn to form a warp yarn exclusion area deprived of the warp yarns;
and a molding step of molding fastener elements of thermoplastic resin or metal such
as zinc alloy in the warp yarn exclusion area.
[0018] With this feature, by forming the warp yarn exclusion area at a portion located inwardly
from the side edge of the fastener tape and molding the fastener elements of thermoplastic
resin or metal such as zinc alloy in the warp yarn exclusion area, a slide fastener
stringer equipped with solid and stable elements can be manufactured easily by using
an ordinary manufacturing apparatus without use of any special manufacturing apparatus.
Therefore, the effects which the present invention achieves are extremely remarkable.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019]
FIG. 1 is a front view of a fastener tape in a state that fastener elements are molded
in a warp yarn exclusion area of the fastener tape.
FIG. 2 is a front view of a fastener tape in which water soluble fiber yarns are disposed.
FIG. 3 is a front view of a fastener tape in a state that fastener elements are formed
in a warp yarn exclusion area of the fastener tape.
FIG. 4 is a front view of a fastener tape in which a core thread is disposed.
FIG. 5 is a front view of a fastener tape in a state tat fastener elements are formed
in a warp yarn exclusion area of the fastener tape.
FIG. 6 is a front view of a fastener tape in which other core thread is disposed.
FIG. 7 is a front view of a fastener stringer.
FIG. 8 is a flow chart showing a process of manufacturing the fastener stringer.
FIG. 9 is a front view showing the warp yarn exclusion area of the fastener tape.
FIG. 10 is a front view of a well known fastener tape.
DESCRIPTIOIN OF THE PREFERRED EMBODIMENTS
[0020] A slide fastener stringer and a method of manufacturing the same according to the
invention will be described. In the slide fastener stringer, as shown in FIG. 1, multi-filaments
of polyester fiber or polyamide fiber are used for warp yarns 2 and weft yarns 3,
and a fastener tape 1 is produced by needle weaving with the weft yarn 3 by double
picks. In the fastener tape 1, a warp yarn exclusion area 12 in which no warp yarns
2 exist by excluding corresponding warp yarns 2 is formed inside over plural pieces
of the warp yarns 2 from a side edge 5, and as a result, plural pieces of the warp
yarns 2 are removed while only the weft yarns 3 are left in the warp yarn exclusion
area. In the warp yarn exclusion area 12, a leg 15 of the fastener element 13 is molded
due to injection molding by using such thermoplastic resin as polyamide and polyacetal
on the left weft yarns 3 at a constant pitch so as to be closely-attached to front
and rear surfaces, thereby producing a fastener stringer as shown in FIG. 7. Alternately,
the fastener elements 13 are formed due to die-cast molding by using such metal as
zinc alloy and aluminum alloy in the warp yarn exclusion area 12, thereby producing
the fastener stringer. In the meantime, because plural pieces of the warp yarns 2
existing between the side edge 5 and the warp yarn exclusion area 12 are covered with
the fastener elements 13 formed in the warp yarn exclusion area 12, they are fixed
with a sufficient mounting strength.
[0021] As means for forming the warp yarn exclusion area 12 in the fastener tape 1, plural
pieces of water soluble fiber yarns 4, for example, water soluble vinylon are disposed
inside over plural pieces of the warp yarns 2 from the side edge 5 of the tape 1 and
the fastener tape is woven, as shown in FIG. 2. Alternatively, it is permissible to
weave a fastener tape 1 of a type in which a core thread 6 is disposed as shown in
FIGS. 4 and 6. In the woven fastener tape 1, the warp yarns as the water soluble fiber
yarns 4 are dissolved in a dying solution in a dying step in the manufacturing process
and removed to form the warp yarn exclusion area 12.
[0022] As for the method of manufacturing the slide fastener stringer, first, the fastener
tape 1 shown in FIG. 2 is needle woven with double picks by using the warp yarn 2
and the weft yarn 3. At this time, plural pieces of water soluble fiber yarns 4 are
disposed as the warp yarns 2 inside of plural pieces of the warp yarns 2 placed along
the side edge 5 of the fastener tape 1. In this weaving step, the fastener tape 1
of a type in which the core thread 6 is used as shown in FIGS. 4 and 6 may be woven.
Next in a heat set step in which the woven fastener tape 1 is heat treated by dry
heat, deviation of stitch in the fastener tape 1 is prevented to stabilize the configuration
of the fastener tape. Thereafter, the fastener tape 1 is sent to the dying step, in
which the fastener tape 1 is passed in a dying solution to dissolve the water soluble
fiber yarns 4, and as a consequence, a warp yarn exclusion area 12 in which no warp
yarn 2 exists is formed in the fastener tape 1.
[0023] After the warp yarn exclusion area 12 is formed, the fastener tape 1 is sent to a
molding step, in which the fastener elements 13 are molded at a constant pitch due
to injection molding by using such thermoplastic resin as polyacetal and polyamide
in the warp yarn exclusion area 12, thereby producing the fastener stringer as shown
in FIG. 7. In the molding step, the fastener elements 13 may be formed due to die-cast
molding by using such metal as zinc alloy and aluminum alloy in the exclusion area
12, thereby producing the fastener stringer. As for the method of manufacturing the
fastener stringer of the present invention, as shown in FIG. 8, the fastener stringer
is produced through the weaving step, the heat set step, the dying step and the molding
step. A produced fastener stringer is cut to a predetermined length, a top stop end
and a bottom stop end or an opening device is mounted on each of right and left fastener
stringers, and then, a slider is loaded thereon, thereby finishing various kinds of
the slide fasteners.
First embodiment
[0024] A slide fastener stringer of a first embodiment of the present invention shown in
FIG. 1 is woven with warp yarns 2 and weft yarns 3 formed of multi-filament yarns
of polyester fiber or polyamide fiber. The fastener tape 1 is produced by needle weaving
with the weft yarn 3 by double picks. In the fastener tape 1, a warp yarn exclusion
area 12, in which only the weft yarns 3 exist, is provided inside of plural pieces
of the warp yarns 2 placed along a side edge 5 by removing plural pieces of the warp
yarns 2. Fastener elements 13 having an appropriate shape are injection molded in
the warp yarn exclusion area 12 by using such thermoplastic resin as polyacetal and
polyamide. A coupling head 14 of the fastener element 13 is projected outward from
the side edge 5 of the fastener tape 1, and the leg 15 or a front end portion 16 of
the leg is formed so as to adhere to the weft yarn 3 existing in the warp yarn exclusion
area 12 and the warp yarn 2 facing the warp yarn exclusion area 12 from both the front
and rear surfaces, thereby producing the fastener stringer shown in FIG. 7.
[0025] By using the warp yarn 2 and weft yarn 3 for the double picks each having a size
of 330 dtex, the fastener tape 1 is woven into an appropriate weaving structure, for
example, a herringbone weaving structure, as shown in FIG. 2. In this case, plural
pieces of water soluble fiber yarns 4 made of water soluble vinylon having 1220 dtex
are disposed inside of plural pieces of the warp yarns 2 placed along the side edge
5 of the fastener tape 1. Because the water soluble fiber yarn 4 is dissolved in water
of 70°C, it is dissolved at a stage where the fastener tape 1 is dyed.
Second embodiment
[0026] A slide fastener stringer of a second embodiment of the present invention shown in
FIG. 3 is woven with warp yarns 2 and weft yarns 3 formed of multi-filament yarns
of polyester fiber or polyamide fiber. The fastener tape 1 is produced by needle weaving
by double pick with the weft yarn 3, and a core thread 6 having a large diameter is
woven into a side edge 5 of the fastener tape 1. As the core thread 6, several pieces
of multi-filament yarns of polyester fiber or polyamide fiber are used, and the same
kind of the multi-filament yarn is braided around it to produce the core thread 6.
A warp yarn exclusion area 12 in which only the weft yarns 3 exist is provided at
a portion corresponding to plural pieces of the warp yarns 2 adjacent to the core
thread 6 in the fastener tape 1. Fastener elements 13 of an appropriate shape are
injection molded in the warp yarn exclusion area 12 by using such thermoplastic resin
as polyacetal and polyamide.
[0027] A coupling head 14 of the fastener element 13 is projected outward from the side
edge 5 of the fastener tape 1, and a leg 15 surrounds the core thread 6 while the
leg 15 and the front end portion 16 fix the weft yarn 3 existing in the warp yarn
exclusion area 12 and the warp yarn 12 facing the warp yarn exclusion area 12 from
the front and rear surfaces, thereby forming the fastener stringer shown in FIG. 7.
As shown in FIG. 4, plural pieces of water soluble vinylon which is water soluble
fiber yarn 4 are disposed adjacent to the core thread 6 arranged along the side edge
5.
Third embodiment
[0028] A slide fastener stringer of a third embodiment of the present invention shown in
FIG. 5 is woven with warp yarns 2 and weft yarns 3 formed of multi-filament yarns
of polyester fiber or polyamide fiber. The fastener tape 1 is produced by needle weaving
by double picks with the weft yarns 3, and a core thread 6 having a small diameter
is woven into a side edge 5 on both the front and rear surfaces of the fastener tape
1. As the core thread 6, a single piece of multi-filament yarn of polyester fiber
or polyamide fiber is used, and the same kind of the multi-filament yarn is braided
around it so as to produce the core thread 6. In the fastener tape 1, the warp yarns
2 are disposed adjacent to the core thread 6, and then, the warp yarn exclusion area
12 in which only the weft yarns 3 exist is provided at a portion corresponding to
plural pieces of the warp yarns 2 adjacent to these warp yarns 2. Then, fastener elements
13 of an appropriate shape are injection molded in the warp yarn exclusion area 12
by using such thermoplastic resin as polyacetal and polyamide. A coupling head 14
of the fastener element 13 is projected outward from the side edge 5 of the fastener
tape 1, and a leg 15 surrounds the core thread 6 while the leg 15 and the front end
portion 16 fix the weft yarn 3 existing in the warp yarn exclusion area 12 and the
warp yarn 2 facing the warp yarn exclusion area 12 from the front and rear surfaces,
thereby producing the fastener stringer shown in FIG. 7. In the fastener tape 1, as
shown in FIG. 6, plural pieces of water soluble vinylon which is water soluble fiber
yarn 4 are disposed adjacent to the core thread 6 arranged on the front and rear surfaces
of the side edge 5.
Fourth embodiment
[0029] If speaking of a method of manufacturing the slide fastener stringer described in
the respective embodiments, the fastener stringer is manufactured according to manufacturing
steps sown in FIG. 8. First, in a weaving step, the warp yarns 2 of 330 dtex formed
of multi-filament yarns of polyester fiber or polyamide fiber are arranged to a predetermined
width of 13 to 16 mm of a predetermined fastener tape 1. At this time, the water soluble
fiber yarns 4 of 1220 dtex, for example, water soluble vinylon are disposed at a position
inward by plural pieces from the warp yarn 2 on the side edge 5. Then, there is disposed,
on the side edge 5, the core thread 6 having a large diameter, for example, a core
thread 6 in which several pieces of multi-filament yarns of polyester fiber or polyamide
fiber are used as a core while the same kind of the multi-filament yarns are braided
around it. Alternatively, on the side edge 5 is vertically disposed the core thread
6 having a small diameter, for example, the core thread 6 in which the a single piece
of multi-filament yarn of polyester fiber or polyamide fiber is used as a core while
the same kind of the multi-filament yarns are braided around it. Then, the weft yarn
3 of the same type as the warp yarn 2 is weft inserted into the arranged warp yarn
3, water soluble fiber yarn 4 or the core thread 6 by double picks in the needle weaving,
so that the fastener tape 1 as shown in FIGS. 2, 4 and 6 is woven with an appropriate
weaving structure, for example, a herringbone weaving structure.
[0030] The woven fastener tape 1 is sent to a next heat set step, in which the fastener
tape 1 is heat treated by dry heat of around 180°C so as to better the texture of
the fastener tape 1 and stabilize is configuration. Thereafter, the fastener tape
1 is sent to a dying step, in which the fastener tape 1 is dyed in a dying solution
of around 130°C. At the same time, the water soluble fiber yarn 4 composed of water
soluble vinylon is dissolved in the dying solution, so that, as shown in FIG. 9, the
water soluble fiber yarns 4 woven into the fastener tape 1 shown in FIG. 6 is dissolved,
and the warp yarn exclusion area 12 in which only the weft yarns 3 are left is formed
when the fastener tape 1 is dyed.
[0031] After dyed, the fastener tape 1 is sent to a molding step to mold the fastener elements
13. In the molding step, the fastener elements 13 having various kinds of shape is
formed in the warp yarn exclusion area 12 in the fastener tape 1 by injection molding
means using such thermoplastic resin as polyacetal and polyamide, thereby to producing
the fastener stringer of resin shown in FIG. 7.
[0032] In the molding step, the fastener elements 13 may be molded in the warp yarn exclusion
area 12 formed in the fastener tape 1 by die-cast molding means using such metal as
zinc alloy and aluminum alloy, thereby manufacturing a metallic fastener stringer.
[0033] Finally, the fastener stringer is cut out to a predetermined length, and a top end
stop and a bottom end stop are mounted on front and rear ends of a cut piece or an
opening device is mounted to combine right and left fastener stringers. Then, a slider
is loaded thereon to finish the slide fastener.
[0034] In the slide fastener stringer of the present invention, thermoplastic resin or the
like is injection molded on a tape side edge to form fastener elements. The fastener
elements are mounted such that their legs pass through the tape. The slide fastener
is finished with a rigid structure and can be applied to not only clothing but also
a product on which a force is applied, such as bags and various kinds of cases.
1. A slide fastener stringer, characterized in that a warp yarn exclusion area (12) deprived of warp yarns (2) is provided inside over
plural pieces of the warp yarns from a side edge (5) of a fastener tape (1), and fastener
elements (13) are formed in the warp yarn exclusion area (12).
2. The slide fastener stringer according to claim 1, characterized in that a core thread (6) is disposed between the side edge (5) of the fastener tape (1)
and the warp yarn exclusion area (12).
3. The slide fastener stringer according to claim 2, characterized in that at least one warp yarn (2) is interposed between the core thread (6) and the warp
yarn exclusion area (12).
4. The slide fastener stringer according to claim 1, characterized in that each of the fastener elements (13) is formed integrally with a coupling head (14)
and a leg (15), the coupling head (14) is disposed outside the side edge (5) of the
fastener tape (1) and the leg (15) is provided through the warp yarn exclusion area
(12).
5. The slide fastener stringer according to claim 1, characterized in that a leg (15) strides over a weft yarn (3) left in the warp yarn exclusion area (12)
on both front and rear surfaces thereof, and a front end portion (16) of the leg is
bonded to a warp yarn (2).
6. A method of manufacturing a slide fastener stringer, characterized by comprising: a weaving step A of weaving with a water soluble fiber yarn (4) as a
warp yarn (2), the water soluble fiber yarn (4) disposed along a side edge (5) of
a fastener tape (1) having a predetermined width; a heat set step B of heat treating
the fastener tape (1); a dying step C of dying the fastener tape (1) while dissolving
the water soluble fiber yarn (4) to form a warp yarn exclusion area (12); and a molding
step D of molding fastener elements (13) by using the warp yarn exclusion area (12).
7. A slide fastener stringer comprising warp yarns (2) and weft yarns (3), characterised in that a separation between a first warp yarn (2) and an adjacent second warp yarn (2) or
an adjacent core thread (6) is at least the combined diameter of two warp yarns (2)
and fastener elements (13) are formed between the first warp yarn (2) and the adjacent
second warp yarn (2) or the adjacent core thread (6).