This application relates generally to woven materials, and more particularly to a woven material configured to have different stretch regions.
Conventional woven material or fabric is used in multiple applications and industries. For example, woven material is used in clothing (e.g., shirts, pants, skirts, etc.), in fashion accessories (e.g., bracelets, watch bands, necklaces, etc.), in electronics (e.g., woven conductive layers, protective outer sheath for optical fiber cables), and other various industrial applications (e.g., rope, tape, protective gear, household/kitchenware). Due to the many uses and applications, conventional woven material is manufactured using specific material or manufactured to include specific physical properties. For example, where the woven material is used to form a bracelet or necklace, it may be desired that the woven material be flexible to contour around the surface in which the woven material is worn (e.g., wrist, neck). Additionally, it may be desired that the woven material forming the bracelet or necklace be durable, flexible and/or capable of withstanding typical wear/treatment of a bracelet or necklace. Furthermore, it may be desired that the woven material forming the bracelet or necklace be capable of forming unique designs or cosmetic embellishments including unique color patterns or portions having varied dimensions (e.g., tapered portions).
When an elastic woven material is fabricated, individual elastic threads are woven in an interlaced pattern to form the woven material. Warp threads are the longitudinal or lengthwise threads and weft threads are the transverse threads. During a weaving operation, the warp threads are held in tension on a frame or on the loom while the weft threads are drawn or inserted between the warp threads. In other words, the weft threads are inserted over and under the warp threads to produce the woven material.
Typically, a tension controller in a loom cannot change the tension in the elastic threads quickly during a weaving operation. The tension controller needs a given thread length to change the amount of tension in the elastic threads. For example, a tension controller can require two to three hundred millimeters of elastic thread to change the tension in the elastic warp threads. Thus, in some situations, a short length of woven material cannot be produced with different stretch regions (e.g., regions of varied stretchiness) . The length of the woven material may be shorter than the minimum length needed to change the tension in the elastic warp threads.
Generally, embodiments discussed herein relate to a woven material that is configured to have different stretch regions. The different stretch regions are created by varying the amounts of tension in subsets of thread during a weaving operation. For example, the length of the woven material can be divided into segments. The threads in each segment may be grouped into subsets of threads. In one embodiment, the warp threads are grouped into subsets of warp threads. The different stretch regions can be created in the woven material by varying the amounts of tension in the subsets of threads in at least one segment of the woven material.
In one aspect, a wearable band includes a woven material that has two or more different stretch regions, where an amount of tension in at least one thread in one stretch region varies from the amount of tension in the threads in another stretch region. For example, in one embodiment the amount of tension in the warp threads varies over the length of the woven material to produce the two or more stretch regions in the woven material. The warp threads can be divided into two or more subsets of warp threads, and the length of the woven material may be divided into two or more segments. The amount of tension in one subset of warp threads is different from the amount of tension in another subset of warp threads in the same segment. Collectively, the particular amounts of tension in all of the subsets of warp threads in a respective segment of the woven material produce a given amount of stretch or tension in the segment. In some embodiments, the wearable band is configured to attach to a housing of the electronic device and to a user. For example, the wearable band can attach to the wrist of a user.
In another aspect, a woven material includes two or more different stretch regions over a length of the woven material. The length of the woven material is divided into two or more segments and each stretch region is associated with a respective segment. A method for producing the woven material may include weaving a first segment of the woven material using one or more thread tension patterns, and weaving a second segment of the woven material immediately adjacent to the first segment using one or more different thread tension patterns. Each thread tension pattern includes tension settings for subsets of warp threads in a segment of the woven material.
In yet another aspect, system for producing a woven material that has two or more different stretch regions can include two or more tension control devices operably connected to a processing device. Each tension control device includes a tension regulator that is configured to adjust an amount of tension in a respective subset of warp threads in the woven material. The processing device may be configured to select a thread tension pattern from a plurality of thread tension patterns for the two or more subsets of warp threads. Each thread tension pattern includes tension settings for the two or more subsets of warp threads in a segment. Each thread tension pattern includes at least one tension setting for one subset of warp threads that differs from the tension settings for another subset of warp threads.
The disclosure will be readily understood by the following detailed description in conjunction with the accompanying drawings, wherein like reference numerals designate like structural elements, and in which:
Reference will now be made in detail to representative embodiments illustrated in the accompanying drawings. It should be understood that the following descriptions are not intended to limit the embodiments to one preferred embodiment. To the contrary, it is intended to cover alternatives, modifications, and equivalents as can be included within the spirit and scope of the described embodiments as defined by the appended claims
Embodiments herein disclose a wearable band that is formed with a woven material that includes two or more regions of different stretchiness, and a method of producing such a woven material. The wearable band may be configured to attach to a housing of an electronic device. The wearable band can also be configured to attach to a user (e.g., a wrist of a user). The different stretch regions may be formed by varying the tension on subsets of the warp threads, the weft threads, or both the warp and weft threads during a weaving operation.
Each stretch region is associated with a segment of the woven material. When a segment of the woven material is fabricated, the tension on one subset of threads, such as one subset of warp threads, can vary from the tension on another subset of warp threads in the same segment of the woven material. For example, the length of a woven material can be divided into multiple distinct segments. Each segment corresponds to a particular stretch region in the woven material. The warp threads in the woven material may be divided into subsets. The amount of tension in a subset of warp threads can vary over the length of the woven material. Collectively, the varied tensions on the different subsets of warp threads produce a woven material that has different stretch regions over the length of the woven material.
These and other embodiments are discussed below with reference to
The wearable band 100 may include a connection device 102 positioned at a first end 104 of the wearable band. Any suitable technique may be used to affix the connection device 102 to the woven material 106 that forms the wearable band 100. Connection device 102 is configured to releasably couple the ends 104, 108 to secure the wearable band 100 to a user. The connection device 102 may be any suitable coupling mechanism capable of releasably coupling the ends 104, 108 together.
As shown in
In some embodiments, the second end 108 may be further secured to the wearable band 100 using a retention loop 116 positioned substantially around the wearable band 100. The retention loop 116 may form an opening (not shown) between the wearable band 100 and the underside of the retention loop 116. The opening receives the second end 108 and positions the second end 108 against a portion of the wearable band 100.
The woven material 106 forming the wearable band 100 may be formed from a large piece of woven material that may be substantially cut or shaped to a desired size. In a non-limiting example, the woven material 106 may be cut from a larger piece of woven material 106 to form the wearable band 100 using a laser cutting process. The laser used in the laser cutting process may cut a larger piece of woven material 106 to produce the desired dimensions of the wearable band 100. Additionally, the laser in the laser cutting process may simultaneously cauterize or round the edges of the woven material 106 forming the wearable band 100 to prevent fraying of the woven material 106. Although discussed herein as being laser cut, it is understood that the woven material 106 may undergo any suitable cutting or shearing process to form the wearable band 100.
Although shown as two distinct portions, it is understood that the wearable band 100 may be formed from a single piece of woven material 106. In one non-limiting example, the single piece of woven material 106 forming the wearable band 100 may have elastic properties, such that the wearable band 100 may be a single, continuous loop of woven material 106 and may stretch around a user's wrist. In another non-limiting example, the single piece of woven material 106 forming the wearable band 100 may have a loop positioned on the first end 102 that may receive the second end 108, and the second end 108 may be folded back onto and coupled to portions of the wearable band 100 to secure the wearable band 100 to a user's wrist. Any suitable coupling component or feature may couple the folded portion of the second end 108 to the wearable band 100 including, but not limited to, Velcro, magnets, clips, and so on.
Additionally, although discussed herein as being formed from a large piece of woven material 106, it is understood that wearable band 100 may be formed by weaving threads to size. That is, in a non-limiting example, the wearable band 100 may not be cut from a larger piece of woven material 106, but rather the woven material 106 may be woven to a desired size of the wearable band 100, and may not undergo a cutting process. However, in the non-limiting example where the wearable band 100 is formed from woven material 106 woven to size, the ends of woven material 106 may undergo additional processes, for example crimping, to improve physical characteristics or visual or tactile features.
When forming the woven material 106 that will be used in the wearable band 100, it may be desirable to produce the woven material with different stretch regions. The wearable band 100 may then have a varying stretchiness over the length and/or width of the wearable band. One region of the band can stretch more (or less) than another region of the wearable band 100.
In one embodiment, both the warp and the weft threads are elastic threads. The elasticity of the warp and weft threads can be the same or the elasticity of the warp threads may be different from the elasticity of the weft threads. Alternatively, warp threads having different amounts of elasticity can be used. Additionally or alternatively, weft threads having different amounts of elasticity can be used.
In
The different stretch regions can be formed by using varying amounts of tension on the warp threads, the weft threads, or both the warp and weft threads. Embodiments described herein produce different amounts of tension in the warp threads during the weaving operation to produce the different stretch regions.
In some embodiments, the tension controller 404 includes multiple tension control devices 404A, 404B, 404C. Each tension control device may be configured to adaptively control the amount of tension in a subset of warp threads provided to the loom 408 by the thread feeding device 406. Each tension control device can adjust the amount of tension in a respective subset of warp threads during a weaving operation. For example, in the illustrated embodiment, tension control device 404A may control, and if desired, vary the amount of tension in the warp threads in the circled area 410 during a weaving operation. The amount of tension in another subset of warp threads may be controlled and adjusted by tension control device 404B, and the amount of tension in the remaining subset of warp threads can be controlled and adjusted by tension control device 404C. Collectively, the varied tensions on the different subsets of warp threads produce a woven material that has different stretch regions over the length of the woven material.
Each tension control device 404A, 404B, 404C may include a tension regulator 414 that is configured to adjust the amount of tension in a subset of warp threads, and a tension sensor 416 configured to determine the amount of tension in each subset of warp threads. Any suitable device can be used as a tension regulator and a tension sensor. In some embodiments, the tension regulator and the tension sensor can be constructed as separate devices. In other embodiments, the tension regulator and the tension sensor can be constructed as a single device.
A memory 412 can be operably connected to the processing device 402. The memory 412 can store instructions, application programs, algorithms, and the like that the processing device 402 can execute to control the operations of the tension controller 404 (e.g., each tension control device 404A, 404B, 404C). The memory 412 can be configured as any suitable type of memory. By way of example only, the memory 412 can be implemented as random access memory, read-only memory, Flash memory, removable memory, or other types of storage elements, individually or in any combination.
The tensile range that is used during the weaving operation is shown on the horizontal axis. In a non-limiting example, the tensile range can include a low tension region, a medium tensile region, a high tensile region, and a maximum tensile region. Collectively, the varied tensions shown in the plots and applied to the three subsets of warp threads produce a woven material that has different stretch regions over the length of the woven material. The tension of the warp threads over the length of the woven material can vary, which produces regions of distinct stretchiness.
The tension settings for the subsets of warp threads 500, 502, 504 that produce a particular tensile value in a segment is known as a thread tension pattern. The thread tension patterns can be stored in a memory, such as memory 412 in
As shown in
The thread tension pattern for the medium tensile value 511 applies a different set of tension settings on the three subsets of warp threads 500, 502, 504. A minimum amount of tension is applied to the first subset of warp threads 500 (see 528), a tension that transitions from a maximum amount of tension to a minimum amount of tension is applied to the second subset of warp threads (see 530), and a maximum amount of tension is applied to the third subset of warp threads (see 532). Thus, different combinations of tension settings can be used to produce a given tensile value. In the illustrated embodiment, seven different thread tension patterns are used to produce the four tensile values (low, medium, high, max). In particular, two different thread tension patterns produce two low tensile values, two different thread tension patterns produce two medium tensile values, two different thread tension patterns produce two high tensile values, and one thread tension pattern produces the maximum tensile value.
Referring now to
To produce the segment 602 when the segment 602 is woven(the segment from L1 to L2), the thread tension pattern includes maintaining the tension on the first subset of warp threads 500 at the maximum amount of tension (see 512), transitioning the tension on the second subset of warp threads 502 from the minimum amount to the maximum amount of tension (see 514), and maintaining the tension on the third subset of warp threads 504 at the minimum amount of tension (see 516).
To produce the segment 604 when the segment 604 is woven (the segment from L2 to L3), the thread tension pattern includes initially maintaining the tension on the first subset of warp threads 500 at the maximum amount of tension (see 518) and then transitioning the tension to the minimum amount of tension (see 520), maintaining the tension on the second subset of warp threads 502 at the maximum amount of tension (see 522), and initially transitioning the tension on the third subset of warp threads 504 from the minimum to the maximum amount of tension (see 524) and then maintaining the tension at the maximum amount of tension (see 526).
To produce the segment 606 when the segment 606 is woven (the segment from L3 to L4), the thread tension pattern includes maintaining the tension on the first subset of warp threads 500 at the minimum amount of tension (see 528), transitioning the tension on the second subset of warp threads 502 from the maximum to the minimum amount of tension (see 530), and maintaining the tension on the third subset of warp threads 504 at the maximum amount of tension (see 532).
To produce the segment 608 when the segment 608 is woven (the segment from L4 to L5), the thread tension pattern can include maintaining the tension on the first subset of warp threads 500 at the minimum amount of tension (see 534), maintaining the tension on the second subset of warp threads 502 at the minimum amount of tension (see 536), and transitioning the tension on the third subset of warp threads 504 from the maximum to the minimum amount of tension (see 538).
Other embodiments can determine the amount of tension in each subset of warp threads differently for a given tensile value. Additionally, the tensile range can be configured in a different arrangement and have different tensile values. And, as described earlier, any suitable arrangement of stretch regions can be produced in other embodiments.
Next, as shown in block 702, a segment of the woven material is fabricated using one or more thread tension patterns. A new thread tension pattern or patterns is selected and another segment is woven using the new thread tension pattern(s) (blocks 704 and 706). A determination may then be made at block 708 as to whether another segment is to be woven. If so, the process returns to block 704. The method returns to block 700 when all of the segments have been woven.
Although the disclosed embodiments have been described as producing different stretch regions in a woven material by varying the amount of tension in two or more subsets of warp threads, other embodiments are not limited to this implementation. Different stretch regions can be created in a woven material by varying the amount of tension in a weft thread. Alternatively, different stretch regions can be produced in a woven material by varying the amount of tension in two or more subsets of warp thread in combination with different amounts of tension on a weft thread.
Additionally, the different stretch regions can be formed by using threads of varying elasticity in addition to varying the amount of tension in two or more subsets of warp threads and/or by varying the amount of tension in a weft thread. For example, threads of different amounts of elasticity can be included in a subset of warp threads, or threads having one amount of elasticity can be included in one subset of warp threads and threads having a different amount of elasticity can be included in another subset of warp threads.
The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the described embodiments. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the described embodiments. Thus, the foregoing descriptions of the specific embodiments described herein are presented for purposes of illustration and description. They are not targeted to be exhaustive or to limit the embodiments to the precise forms disclosed. It will be apparent to one of ordinary skill in the art that many modifications and variations are possible in view of the above teachings.
This application claims the benefit under 35 U.S.C. § 119(e) of U.S. Provisional Patent Application No. 62/129,912, filed Mar. 8, 2015 and titled “Woven Band With Different Stretch Regions,” the disclosure of which is hereby incorporated herein by reference in its entirety.
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