i created with php zip ( http://php.net/manual/de/book.zip.php ) a zip file
now i have to send it to the browser / force a download for it.
You need to do it this way, otherwise your zip will be corrupted:
$size = filesize($yourfile); header("Content-Length: \".$size.\"");
So content-length header needs a real string, and filesize returns and integer.