Zipper Profile Cut and Stretch for Audible Feedback

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Solution Overview

Problem

Existing zipper technologies for reclosable packages fail to provide a superior audible clicking sound and tactile feel, maintain closure strength, especially when filled with air, and are inefficient in production rates and costs.

Innovation Solution

The zipper profiles are partially cut and stretched, with specific cut orientations and depths, and materials like high modulus resins are used to enhance sound production and maintain strength, while the cutting and stretching process is optimized to create gaps that improve tactile feedback and leak resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the zipper profile is deformed to produce audible clicking sound and tactile feel, then the user experience is improved, but the closure strength and leak resistance deteriorate

Engineering Contradiction:

Improveaudible clicking sound and tactile feelVSAvoidclosure strength and leak resistance

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The zipper profile is segmented into multiple sections with different properties: the body portion maintains continuous material structure for strength, while the distal end features controlled gaps and deformations for sound production. This segmentation allows each region to fulfill its specific function without compromising the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the zipper profile are given different structural qualities: the proximal and middle sections have continuous material for structural integrity, while the distal end section has intentional gaps and deformations. This local differentiation enables the zipper to simultaneously achieve strong closure and audible/tactile feedback.

Inventive Principle:

Principle #3Local quality

2Productivity

If traditional zipper manufacturing methods are used, then production costs are controlled, but production rates and efficiency are limited

Engineering Contradiction:

Improveproduction rateVSAvoidmanufacturing cost

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The desired gap structure and deformation pattern are built into the zipper profile during the extrusion process itself, rather than requiring subsequent cutting or machining operations. This preliminary formation of features directly in the extrusion die eliminates additional manufacturing steps and reduces costs.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention replaces traditional mechanical post-processing methods (cutting, punching, or forming gaps after extrusion) with a streamlined extrusion process that directly creates the gap structure. This substitution of manufacturing approach reduces complexity and improves production efficiency.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of operation

If the zipper profile is cut or excised to create gaps, then audible sound and tactile feel are achieved, but the structural integrity and closure strength are compromised

Engineering Contradiction:

Improveaudible clicking soundVSAvoidclosure strength

Core Design Contradiction:

Ease of operationVSStrength

Solution Approach 1:

The zipper profile is segmented into multiple sections with different properties: the body portion maintains continuous material structure for strength, while the distal end features controlled gaps and deformations. This segmentation allows each region to fulfill its specific function without compromising the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The zipper profile utilizes composite material properties where the continuous polymer matrix provides structural strength while embedded gap structures and deformations provide sound production capability. The composite structure integrates both functional requirements at the material level.

Inventive Principle:

Principle #40Composite materials

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution achieves a superior audible and tactile experience, maintains closure strength, reduces seepage, and increases production efficiency while decreasing costs, ensuring effective sealing and sound production.

Implementation Method 1

the zipper profiles are partially cut and stretched

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Implementation Method 2

in order to obtain audible clicking sounds and a tactile feel during subsequent consumer operation

Methodology Applied

Scientific EffectSound production through material deformation: Acoustic Emission

Data Source

PatentUS9260225B2Zipper profile manufactured by cut and stretch methods

Publication Date: 2016.02.16 ILLINOIS TOOL WORKS INC

AI summary

The disclosure relates to a zipper for a reclosable bag wherein the zipper is designed to make additional sound during operation, and further provide an increased tactile response. The zipper profile is manufactured by forming cuts in the profile, and then the profile is stretched so that the cuts become gaps. These gaps cause additional sound during operation of the zipper.