PATENT DOCUMENT

Publication Number: US-11518138-B2
Application Number: US-201414578319-A
Country: US
Kind Code: B2

Title: Using woven fibers to increase tensile strength and for securing attachment mechanisms

Abstract:
Embodiments disclosed are directed to a woven fabric band that is capable of being secured to another object using threads or the band itself. The woven fabric band may include an inner layer having a first temperature melting point and an outer layer having a second temperature melting point that is higher than the first temperature melting point. When heat having the first temperature is applied to the woven fabric band, the inner layer of the woven fabric band melts while the outer layer remains in its original state. When the inner layer melts, the inner layer conforms to a first shape. As a result of the inner layer conforming to the first shape, the outer layer also conforms to the same shape.

Claims:
We claim: 
     
       1. A band assembly comprising:
 a woven band comprising:
 an inner layer of first woven fabric threads having a first temperature melting point; 
 an outer layer of second woven fabric threads having a second temperature melting point that is higher than the first temperature melting point, wherein the outer layer forms a sheath that surrounds the inner layer on opposing sides of the inner layer; and 
 first holes extending through the inner layer and the outer layer of the woven band; 
 wherein when heat having a first temperature is applied to the woven band, the inner layer conforms to a first shape; 
 wherein when the inner layer conforms to the first shape, the outer layer is configured to conform to a second shape, wherein the second shape is a shape of the inner layer; 
 
 an attachment mechanism having an end of the woven band within the attachment mechanism and having second holes that are overlapping the first holes; and 
 interlock mechanisms each extending through both of a corresponding one of the first holes and a corresponding one of the second holes to secure the attachment mechanism to the woven band, the interlock mechanisms each comprising a first portion extending from a first side of the attachment mechanism and a second portion extending from a second side of the attachment mechanism, opposite the first side, the first portion being received by the second portion. 
 
     
     
       2. The band assembly of  claim 1 , wherein when heat is applied to the woven band, the outer layer is not damaged. 
     
     
       3. The band assembly of  claim 1 , wherein the first temperature melting point is about 110 degrees Celsius. 
     
     
       4. The band assembly of  claim 1 , wherein the second temperature melting point is about 220 degrees Celsius. 
     
     
       5. The band assembly of  claim 1 , wherein a first portion of the woven band is heated to cause the inner layer at the first portion to conform to the first shape without heating a second portion of the woven band. 
     
     
       6. The band assembly of  claim 1 , wherein the first shape is a logo. 
     
     
       7. The band assembly of  claim 1 , wherein the first shape is selected from a group comprising a hole, a protrusion, a nub, a ridge, a link and a boss. 
     
     
       8. The band assembly of  claim 1 , wherein the first shape is associated with a mold. 
     
     
       9. A band for a device that tells time, the band comprising:
 a woven portion comprising:
 an inner layer of first woven fabric threads having a first temperature melting point; 
 an outer layer of second woven fabric threads having a second temperature melting point that is higher than the first temperature melting point, wherein the outer layer extends about a periphery of the inner layer; and 
 first holes extending through the inner layer and the outer layer of the woven portion; 
 
 an attachment mechanism having an end of the woven portion within the attachment mechanism and having second holes that are overlapping the first holes; and 
 interlock mechanisms each extending through both of a corresponding one of the first holes and a corresponding one of the second holes to secure the attachment mechanism to the woven portion, the interlock mechanisms each comprising a first portion extending from a first side of the attachment mechanism and a second portion extending from a second side of the attachment mechanism, opposite the first side, the first portion being received by the second portion. 
 
     
     
       10. The band of  claim 1 , wherein the first temperature melting point is about 110 degrees Celsius. 
     
     
       11. The band of  claim 1 , wherein the second temperature melting point is about 220 degrees Celsius. 
     
     
       12. The band of  claim 1 , wherein a first portion of the woven portion is heated to cause the inner layer at the first portion to conform to a shape without heating a second portion of the woven portion. 
     
     
       13. The band of  claim 12 , wherein the shape is selected from a group comprising a hole, a protrusion, a nub, a ridge, a link and a boss. 
     
     
       14. The band of  claim 12 , wherein the shape is associated with a mold.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a nonprovisional patent application of and claims the benefit to U.S. Provisional Patent Application No. 61/919,508, filed Dec. 20, 2013 and titled “Securing Woven Fibers to Attachment Mechanisms” and to U.S. Provisional Patent Application No. 61/919,528 filed Dec. 20, 2013 and titled “Using Woven Fibers to Increase Tensile Strength and Minimize Space,” the disclosures of which are hereby incorporated herein by reference in their entireties. 
    
    
     TECHNICAL FIELD 
     The present disclosure is directed to securing woven fibers to an attachment mechanism or an attachment system and further, using woven fibers to increase tensile strength and minimize space. In some embodiments, the woven fibers may be attached to the attachment mechanism or the attachment system in a manner that increases tensile strength and minimizes space. Specifically, the present disclosure is directed to a method and system for enabling a woven fiber, or other such material, to be formed in such a way as to enable the woven fiber to securely attach to one or more attachment mechanisms while enabling the woven fiber to keep its original or intended shape and structure. In other embodiments, the woven fiber may be secured to an object using a plurality of threads of the woven fiber. 
     BACKGROUND 
     Typically, when securing a woven fabric or other material to another object, the woven fabric needs a termination point. The termination point may be made by stitching a first portion of the woven fabric to itself, a second portion of the woven fabric or to another object. However, such configurations may cause the woven fabric to change its shape, width or structure or the additional stitching may cause the width of the object and/or the woven fabric to increase. This increase in width may not be desirable. Additionally, the stitching may cause undesirable aesthetics on the woven fabric or undesirable aesthetics on the object. 
     It is with respect to these and other general considerations that embodiments have been made. Also, although relatively specific problems have been discussed, it should be understood that the embodiments should not be limited to solving the specific problems identified in the background. 
     SUMMARY 
     This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description section. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter. 
     One or more embodiments of the present disclosure provide a woven fabric band that is capable of being secured to another object. In certain embodiments, the woven fabric band comprises an inner layer having a first temperature melting point and an outer layer having a second temperature melting point that is higher than the first temperature melting point. When heat, having the first temperature, is applied to the woven fabric band, the inner layer of the woven fabric band melts or becomes more malleable while the outer layer remains in its original state. When the inner layer melts, the inner layer conforms to a first shape. As a result of the inner layer conforming to the first shape, the outer layer also conforms to the same shape. 
     In another embodiment, a method for generating a woven fabric band is disclosed. According to such embodiments, the method includes creating an inner layer of the woven fabric band with the inner layer having a first temperature melting point. In certain embodiments, a sheath surrounds the inner layer. Further, the sheath has a second temperature melting point that is different from the temperature melting point of the inner layer. The method further includes applying heat to the woven fabric band that causes the inner layer to melt and conform to a shape without melting or damaging the sheath. 
     In still yet other embodiments, a method of generating a securement mechanism for a woven fabric band is disclosed. According to this method, the woven fabric band is placed into a mold. Heat is applied to a first side and a second side of a first portion of the woven fabric band. However, heat is not applied to a first side and a second side of a second portion of the woven fabric band. The heat that is applied to the first side and the second side of the first portion of the woven fabric band causes the first portion of the woven fabric band to melt. As the first portion melts, the first portion conforms to the shape of the mold and may generate the securement mechanism. A channel in the mold causes the melted first portion of the woven fabric band to flow away from the second portion of the woven fabric band. As a result, the melted first portion of the woven fabric band may be easily removed from the second portion of the woven fabric band. 
     In still yet other embodiments, a method and system for securing an object to a woven fabric band is disclosed. As part of this process, the woven fabric band may be cut, scarred, or manufactured so as to expose a plurality of threads from a portion of the woven fabric band. An object that is to be secured to the woven fabric band is then aligned with the woven fabric band or to the plurality of threads. The object is then secured to the woven fabric band using the plurality of threads. In certain embodiments, the plurality threads are wrapped around or stitched to the object. Once the plurality of threads have been wrapped around or stitched to the object, the plurality of threads are exposed to a heating process. The heating process may be performed with one or more heat sources. The heat source causes the plurality of threads to melt. The melting process, and the subsequent cooling process, causes the plurality of threads to become more rigid which increases the tensile strength of the plurality of threads. Further, the melting process causes the plurality of threads to decrease in size. Due to the decrease in size, the threads may then be hidden from view by coupling a second object to the object that is secured to the woven fabric band. 
     Also disclosed is a woven fabric band comprising an inner layer having a first temperature melting point and an outer layer having a second temperature melting point that is higher than the first temperature melting point. In certain embodiments, the inner layer has a plurality of threads extending therefrom. The plurality of threads are used to stitch an assembly to the woven fabric band. Further, the plurality of threads increase in tensile strength and decrease in width when heat having the first temperature melting point is applied to the plurality of threads. 
     In yet another embodiment, a method for creating a woven fabric band for securement to an object is disclosed. According to one or more embodiments, an inner layer having a first temperature melting point is created. The inner layer is then surrounded with a sheath. In certain embodiments, the sheath has a second temperature melting point that is different from the first temperature melting point. The method also includes exposing, on a distal end of the woven fabric band, a plurality of threads. The plurality of threads are used to stitch the object to the distal end of the woven fabric band. Once the object has been stitched to the distal end of the woven fabric band, the plurality of threads are exposed to a heat source. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG.  1 A  illustrates an exemplary woven fabric band having a plurality of securement features according to one or more embodiments of the present disclosure; 
         FIG.  1 B  illustrates a close-up view of the woven fabric band of  FIG.  1 A  having the plurality of securement features according to one or more embodiments of the present disclosure; 
         FIG.  2    illustrates a cross-sectional view of a woven fabric band according to one or more embodiments of the present disclosure; 
         FIG.  3    illustrates a cross-sectional view of the woven fabric band with a plurality of heating mechanisms being inserted into the woven fabric band according to one or more embodiments of the present disclosure; 
         FIG.  4    is a flow diagram that illustrates a method for generating one or more securement features of the woven fabric band according to one or more embodiments of the present disclosure; 
         FIG.  5    is a flow diagram that illustrates a method for creating a woven fabric band according to one or more embodiments of the present disclosure; 
         FIG.  6 A  illustrates an exemplary woven fabric band according to one or more embodiments of the present disclosure; 
         FIG.  6 B  illustrates an object that is to be coupled to the woven fabric band according to one or more embodiments of the present disclosure; 
         FIG.  6 C  illustrates a woven fabric band that is coupled to an object using a plurality of threads according to one or more embodiments of the present disclosure; 
         FIG.  6 D  illustrates a woven fabric band that is coupled to an object using a plurality of threads that have been subjected to a heating process according to one or more embodiments of the present disclosure; 
         FIG.  7    illustrates a cross-sectional view of a woven fabric band according to one or more embodiments of the present disclosure; 
         FIG.  8    illustrates a cross-sectional view of the woven fabric band with a plurality of threads extending therefrom according to one or more embodiments of the present disclosure; and 
         FIG.  9    is a flow diagram that illustrates a method for securing an object to a woven fabric band according to one or more embodiments of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     Various embodiments are described more fully below with reference to the accompanying drawings, which form a part hereof, and which show specific exemplary embodiments. However, embodiments may be implemented in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the embodiments to those skilled in the art. The following detailed description is, therefore, not to be taken in a limiting sense. 
     The various embodiments described herein are directed to using a fabric material, or threads of the fabric material, to secure various objects to a band or a strap or other such mechanism. In some embodiments described herein, the fabric material may have an inner layer and an outer layer. The inner layer may have a first temperature melting point while the outer layer has a second temperature melting point. Thus, as the inner layer is heated and subsequently deforms due to the heating process, the outer layer may conform to the shape of the inner layer. However, because the outer layer has a higher temperature melting point, the heating process may not affect the aesthetics of the outer layer. 
     As discussed above, in some embodiments, threads of the band or strap may be used to secure an attachment mechanism or other object to the band or strap. The threads may be used to stitch the attachment mechanism to the band or strap. The threads may then be heated or otherwise melted. The heating process and subsequent cooling process may increase the tensile strength of the threads and also decrease a width, a circumference or other measurement of the threads. 
     Turning to the figures,  FIG.  1 A  illustrates an exemplary woven fabric band  100  having a plurality of securement features according to one or more embodiments of the present disclosure. Although the term fabric is used herein, it is contemplated that the embodiments and methods described herein may be applied to various materials that can be woven together. It is also contemplated that the material, when woven together, may be cut, manufactured or manipulated into various shapes, articles and objects having varying dimensions. Non-limiting examples of the fabric may include nylon and other such polymers. 
     The woven fabric, or portions of the woven fabric, may be heated to a melting point (e.g., a point at which the heated portion melts). When the woven fabric is melted, the melted portion may be manipulated or formed into various shapes, protrusions, depressions, graphics and the like. However, due to the nature of the construction of the woven material, (e.g., an outer layer of the woven fabric being more heat resistant than an inner layer of the woven fabric) the outer layer conforms to the shape of the inner layer while still maintaining its aesthetic properties (e.g., color, texture etc.). 
     As shown in  FIG.  1 A , the woven fabric band  100  may be a thin band that may be secured to another object. In some embodiments, the object may be a mobile phone, a device that tells time, a health monitoring device or assistant, a purse, bracelet or other article of clothing. Although a flat thin band is specifically shown and described herein, the woven fabric band  100  may be made in any shape. For example, if the woven fabric band  100  was to be attached to a purse, the woven fabric band may be circular in shape. 
     In certain embodiments, the woven fabric band  100  may have one or more through holes  110  or apertures that may be used to secure the woven fabric band  100  to another object. As shown in  FIG.  1 A , the through holes  110  may be formed directly in the woven fabric band  100 . The through holes  110  may be formed using a method such as method  400  described herein with respect to  FIG.  4   . 
     In certain embodiments, the through holes  110  may be formed on a distal end  120  of the woven fabric band  100 . Although the through holes  110  are shown on the distal end  120  of the woven fabric band  100 , the through holes  110 , and associated securement features, may be disposed on multiple sides and/or ends of the woven fabric band  100 . 
     As shown in  FIG.  1 A  and  FIG.  1 B , the distal end  120  of the woven fabric band  100  may have a smooth surface. In embodiments, the heating and melting processes described herein may cause a portion of the woven fabric band  100  to change its structure and appearance. However, because the distal end  120  of the woven fabric band  100  is smooth, the distal end  120  of the woven fabric band  100  may be moveably coupled to another object, such as, for example, object  150 . In another embodiment, the distal end  120  of the woven fabric band  100  may be configured to pivot within an object  150 . As such, it may be desirable that the distal end  120  of the woven fabric band  100  has a smooth surface. Although a smooth surface is specifically mentioned and shown, the distal end  120  of the woven fabric band  100  may have other textures (e.g., rough, slatted, etc.) as well as various shapes, sizes and dimensions. 
     As briefly discussed above, although the through holes  110  are shown on the distal end  120  of the woven fabric band  100 , the through holes  110  may be formed on a proximal end of the woven fabric band  100 . In addition, one or more through holes  110  may be formed on other portions of the woven fabric band  100 , such as, for example, in a middle or center portion of the woven fabric band  100 . The through holes  110  may be configured in a variety of shapes, such as, for example, circular, triangular, rectangular, square, and the like. In some embodiments, the through holes  110  at a first location on the woven fabric band  100  may have a first shape, size or dimension while one or more through holes  110  at a second location on the woven fabric band  100  have a second, different shape, size or dimension. 
     In certain embodiments, the through holes  110  may be configured to receive one or more interlock mechanisms. As shown in  FIG.  1 A  and  FIG.  1 B , the interlock mechanisms may include a top portion  130  and a bottom portion  140 . In embodiments, the top portion  130  may be received by the bottom portion  140 . Alternatively, the top portion  130  may be configured to receive the bottom portion  140 . Further, the top portion  130  and the bottom portion  140  may be configured to secure an object, such as object  150 , to the woven fabric band  100  using object through holes  160  that align with through holes  110  of the woven fabric band  100 . When the object through holes  160  are aligned with the through holes  110 , the top portion  130  and the bottom portion  140  of the interlock mechanisms may be used to secure the object  150  to the woven fabric band  100 . 
     Although a top portion  130  and a bottom portion  140  are specifically disclosed, the object  150  may be secured to the woven fabric band using other attachment means, mechanisms and so on. For example, the object  150  may be secured to the woven fabric band  100  using various threads of the woven fabric band such as will be described below. 
       FIG.  2    illustrates a cross-sectional view of a woven fabric band  100  according to one or more embodiments of the present disclosure. As shown in  FIG.  2   , the woven fabric band  100  includes an outer layer  210  and an inner layer  220 . In certain embodiments, the outer layer  210  may be a first type of material (woven or otherwise) and the inner layer  220  may be a second type of material (woven or otherwise). In other embodiments, the outer layer  210  and the inner layer  220  may be the same type of material but have different temperature melting points. For example, the temperature melting point of the outer layer  210  may be 220 degrees Celsius while the temperature melting point of the inner layer  220  may be 110 degrees Celsius. In still yet other embodiments, the outer layer  210  may be made of a first material and have a first temperature melting point (e.g., 220 degrees Celsius) and the inner layer  220  may be made of a second material and have a second temperature melting point (e.g., 110 degrees Celsius). 
     In certain embodiments, the outer layer  210  may be a sheath that has a cross-hatch configuration. In such embodiments, the inner layer  220  may be comprised of another material or fiber. As shown in  FIG.  2   , the outer layer  210  may surround the inner layer  220 . It is also contemplated that the outer layer  210  may be configured to removably slide over or otherwise be coupled to the inner layer  220  prior to applying heat to the woven fabric band  100 . 
     As discussed above, the inner layer  220  may have a lower temperature melting point than the outer layer  210 . As a result, when heat is applied to the woven fabric band  100 , the inner layer  220  may melt or become more malleable. As such, the inner layer  220  may be manipulated (e.g., using a mold or other such form factor mechanism) to take a desired form or shape. As the inner layer  220  melts and is manipulated into a new shape, the outer layer  210  may conform to the new shape of the inner layer  220 . However, because the outer layer  210  has a higher temperature melting point when compared to the inner layer  220 , the outer layer  210  does not melt. As such, the outer layer  210  may retain its original aesthetic look, feel and texture (i.e., the outer layer  210  is not damaged or noticeably changed due to the melting process of the inner layer  220 ). 
     The process described above enables the inner layer  220  to take a variety of shapes and forms including, but not limited to three-dimensional shapes, logos, holes, depressions, protrusions, nubs, ridges, links, bosses and the like. As the inner layer  220  takes these various forms, the outer layer  210  conforms to the new shape of the inner layer  220 . In some embodiments, the outer layer  210  is flexible but durable. As such, the outer layer  210  may maintain its original aesthetic values. For example, different colors and color combinations could be used for the outer layer  210  and the inner layer  220 . Further, the inner layer  220  and/or the outer layer  210  may be transparent or translucent to create different cosmetic effects. 
     In some embodiments, a first portion of the woven fabric band  100  may be subjected to a heating process while a second, different portion of the woven fabric band  100  is not subjected to the heating process. For example, one or more “links” could be created on the woven fabric band  100  by melting different portions of the woven fabric band  100  at various intervals. In such embodiments, the melted portions may become semi-rigid when subsequently cooled, while the un-melted portions of the woven fabric band  100  are flexible. The woven fabric band  100 , or one or more of the inner layer  220  and the outer layer  210 , have different thicknesses. Based on the thickness of the outer layer  210  and the inner layer  220 , different cosmetic effects may be created. 
       FIG.  3    illustrates a cross-sectional view of the woven fabric band  100  with a plurality of heating mechanisms  300  being inserted into the woven fabric band  100  according to one or more embodiments of the present disclosure. In certain embodiments, the heating mechanisms  300  may be part of a mold. In other embodiments, the heating mechanisms  300  may be the actual mold (i.e., the portion of the woven fabric band  100  that comes into contact with the plurality of heating mechanisms  300  conforms to the shape of the plurality of heating mechanisms  300 ). 
     In certain embodiments, the mold enables the reflow of one or more ends of the woven fabric band  100  into three-dimensional shapes. The three-dimensional shapes may enable the woven fabric band  100  to be mechanically coupled to another object. For example, the heating mechanisms  300  may be used to create the distal end  120  and the through holes  110  of the woven fabric band  100  shown and described with respect to  FIG.  1 A  and  FIG.  1 B . 
     In embodiments, each of the plurality of heating mechanisms  300  include a heating element  310  disposed on a distal end. The heating elements  310  may cause the heated portions of the woven fabric band  100  to conform to the shape of the heating elements  310  such as discussed above. Further, and as shown in  FIG.  3   , the heating elements  310  may be used to apply heat to a top side of the woven fabric band  100  and a bottom side of the woven fabric band  100  to create one or more through holes  110  ( FIG.  1   ). Although the heating mechanisms  300  are shown on both sides of the woven fabric band  100 , the heating mechanisms  300  may be used on either the top side or the bottom side of the woven fabric band  100 . 
     In some cases, the heating mechanisms  300  include one or more overflow channels  320 . The overflow channels are configured to enable the melted portions of the woven fabric band  100  to move away from the through holes  110  and the woven fabric band  100 . Once the melted portions have been moved away from the woven fabric band  100 , the melted material may be permanently removed from the woven fabric band  100  (e.g., by cutting the material). 
       FIG.  4    is a flow diagram that illustrates a method  400  for generating one or more securement features of a woven fabric band according to one or more embodiments of the present disclosure. In certain embodiments, the method  400  may be used to generate one or more through holes, such as, for example, through holes  110  of the woven fabric band  100  shown and described above with respect to  FIG.  1 A  and  FIG.  1 B . In addition, the method  400 , or portions of the method  400 , may be used to generate various ornamentations for the woven fabric band. Such ornamentations include a logo, a hole, a depression, a protrusion, a nub, a ridge, a link, a boss and the like. 
     Method  400  begins when the woven fabric band is inserted  410  into a mold. In certain embodiments, when inserted into the mold, the woven fabric band may have a generic shape and/or structure (e.g., it has not been subjected to a heating process). In other embodiments, the woven fabric band, or portions thereof, may have previously been subjected to a heating process that causes the woven fabric band (or portions thereof) to take a particular shape or structure. One exemplary structure is shown with respect to  FIG.  1 A  and  FIG.  1 B . 
     Once the woven fabric band has been inserted into the mold, flow proceeds to operation  420  in which a first region of the woven fabric band is heated. The first region of the woven fabric band may be heated by one or more heating elements disposed on a distal end of a portion of the mold, such as, for example, heating mechanisms  300  and heating elements  310  shown in  FIG.  3   . The heating mechanisms may be configured in a particular shape or orientation. Thus, when the heating mechanisms come into contact with the woven fabric band, the portions of the woven fabric band that are heated conform to the shape of the mold and/or the heating mechanisms. 
     In certain embodiments, the mold may be comprised of many different heating elements that may be selectively activated in order to heat different portions of the woven fabric band. In another embodiment, the entire mold may be heated at the same time so as to enable the woven fabric band to take a desired shape or orientation. In still yet other embodiments, the heating mechanisms of the mold may be heated to the temperature melting point of the outer layer. Once the heating mechanisms have been heated to the temperature melting point, the heating mechanisms may be inserted into the woven fabric band to create one or more through holes. 
     As discussed above, the heating mechanisms may be used to heat and melt certain portions of the woven fabric band. As a result, the shape and structure of the heated portions of the woven fabric band may be changed while a non-heated portion retains its original shape and structure. In embodiments, the heating mechanisms are placed on a top side and a bottom side of the woven fabric band. As the heating mechanisms are inserted into the woven fabric band, each heating mechanism melts a portion of the outer layer and the inner layer of the woven fabric band. 
     The melting process may slightly shrink the heated portions of the woven fabric band. Thus, in order to achieve a thickness of about 1.4 mm, the woven fabric band may need to have an original thickness of 1.7 mm. In another embodiment, the heating and melting process may cause the heated portion (once cooled) to be stronger and/or more rigid than the un-melted portions of the woven fabric band. Thus, the melted portion of the woven fabric band may be better suited for use as a securement mechanism. 
     Referring back to  FIG.  4   , once a portion of the woven fabric band has been heated, flow proceeds to operation  430  and the heated or melted portions of the woven fabric band flow away from the non-heated or un-melted portions of the woven fabric band. In embodiments, reflow of the melted portions of the woven fabric band may be achieved using one or more flow channels disposed in, or associated with, the mold. In certain embodiments, the one or more flow channels may be integrated within the heating mechanisms such as shown above with respect to  FIG.  3   . 
     Flow then proceeds to operation  440  in which the heated or melted portions of the woven fabric band are removed (if necessary). In certain embodiments, the heated or melted portions of the woven fabric band may be removed from the woven fabric band when the heated or melted portions have cooled or are in the process of cooling. The heated or melted portions may be removed using a knife, scissors, a laser and the like. 
       FIG.  5    is a flow diagram that illustrates a method  500  for creating a woven fabric band according to one or more embodiments of the present disclosure. In certain embodiments, the method  500  may be used to create a woven fabric band such as shown above with respect to  FIG.  1 A ,  FIG.  1 B  and  FIG.  2   . As discussed above with respect to these figures, the method  500  may be used to create ornamental designs or shapes on the woven fabric band including holes, depressions, logos, ridges, bosses, links, protrusions and the like. The method  500  may also be used to generate a number of different three-dimensional shapes and configurations. 
     Method  500  begins at operation  510  in which an inner layer of a woven fabric is created. In certain embodiments, the inner layer may be the inner layer  220  described above with respect to  FIG.  2   . The inner layer may be a woven fabric that has a low temperature melting point (e.g., around 110 degrees Celsius). The inner layer may be configured to be malleable when heated which enables the inner layer to be formed into the different shapes and configuration described above. Further, when cooled (e.g., after the heating process) the inner layer may be formed or otherwise change from a malleable material into a rigid material that prevents the woven fabric band from stretching or losing its shape. 
     Flow then proceeds to operation  520  in which the inner layer is surrounded by an outer layer of woven fabric. In certain embodiments, the outer layer may be the outer layer  210  described above with respect to  FIG.  2   . The outer layer may be a woven fabric that has a higher temperature melting point than the inner layer. For example, the outer layer may have a temperature melting point of 220 degrees Celsius. The outer layer may be configured to conform to the shape of the inner layer as the inner layer is manipulated when heat is applied. Because the outer layer has a higher temperature melting point than the inner layer, the outer layer is not damaged (e.g., does not show any residual markings, defects and the like) caused by the heating process. Thus, the outer layer may keep its original colors, ornamentations and the like. In other embodiments, the heating process may cause a desired change in the texture, color, or shape of the outer layer. 
     Operation  530  provides that the inner layer is heated with a first temperature. As the outer layer surrounds the inner layer, one or more embodiments provide that the heat is applied to the inner layer through the outer layer. In such embodiments, the heat that is applied is hot enough to cause the inner layer to melt or become more malleable but is not hot enough to affect the outer layer. In certain embodiments, the heat may be applied when the woven fabric is in a mold or other such mechanism that causes the woven fabric to conform to a desired shape when heated. The heat may be applied locally to one or more portions of the inner layer or to the inner layer as a whole. 
     Once heat having a first temperature has been applied to the inner layer, flow proceeds to operation  540  and the inner layer is formed into a desired shape or orientation. In embodiments, the orientation or shape may be in conformity with a mold, a stencil or the like. As the inner layer conforms to the shape, the outer layer that surrounds the inner layer takes the same shape. Thus, a woven fabric band may be created having a desired shape while still maintaining desired aesthetics. 
       FIG.  6 A - FIG.  6 D  illustrate an exemplary woven fabric band  600  having a plurality of threads  640  for securing an object  630  to the woven fabric band  600  according to one or more embodiments of the present disclosure. Although the term fabric is used herein, it is contemplated that the embodiments and methods described herein may be applied to various materials that can be woven together to form a strap, band, article of clothing and the like. It is contemplated that the material, when woven together, may be cut, manufactured or manipulated into various shapes, objects and designs. Non-limiting examples of the fabric may include nylon and other such polymers. In certain embodiments, the woven fabric, or portions thereof, may be heated to a point where the heated portion melts. When the woven fabric has melted, the melted portion may be manipulated or formed into various shapes, protrusions, graphics and the like. However, due to the nature of the construction of the woven material (e.g., an outer layer of the woven fabric being more heat resistant than an inner layer of the woven fabric), the inner layer may melt and take a desired shape while the outer layer does not melt but conforms to the shape of the inner layer while still maintaining its aesthetic properties (e.g., color, texture etc.). 
     As discussed above, in some embodiments a woven fabric band may be secured to an attachment mechanism or other object using various threads. In such embodiments, the threads may be part of the inner layer, the outer layer, or a combination thereof. In addition, the attachment mechanism discussed below may be placed on one end of the woven fabric band while the attachment mechanism discussed above with respect to  FIG.  1 A  and  FIG.  1 B  is attached to a different end of the woven fabric band. 
     Referring to  FIG.  6 A - FIG.  6 D , a woven fabric band  600  may be a thin band and may be similar to the woven fabric band  100  described above. As such, the woven fabric band  600  may have one or more patterns, protrusions, depressions, rivets or designs displayed thereon. 
     As briefly discussed above, an object  630  may be secured to the woven fabric band  600 . The object  630  may be a pin, a clasp, a hook or other such mechanism that enables an object  630  to be secured to a second object or to the woven fabric band  600  itself. The embodiments disclosed herein may be used in conjunction with a mobile phone, a device that tells time, a health monitoring device or assistant, a purse, a bracelet or other such article of clothing. Further, although a flat thin band is specifically shown and described herein, the woven fabric band  600  may be formed in any shape having a variety of dimensions. For example, if the woven fabric band  600  was to be used to as a strap for a purse, the woven fabric band  600  may be circular in shape. 
     In certain embodiments, the woven fabric band  600  has a distal end  610  from which a plurality of threads may be exposed. The plurality of threads may be exposed as part of the manufacturing process (e.g., deliberately exposed when the layers of the woven fabric band  600  are constructed) or may be exposed by cutting or tearing at least a portion of the woven fabric band  600 . The woven fabric band  600  may have an inner layer and an outer layer such as described above. In such embodiments, the plurality of threads may be part of the inner layer of the woven fabric band  600 , the outer layer of the woven fabric band or a combination thereof. 
     As shown in  FIG.  6 A , the distal end  610  of the woven fabric band  600  may also have an alignment slot  620 . The alignment slot  620  may be used to align an object with the woven fabric band  600 . In embodiments where the object to be coupled to the woven fabric band  600  is a hook or a clasp, the alignment slot  620  may be formed in a shape that corresponds to the object. The slot may also be used to enable the object, or a portion of the object, to rotate about an axis. 
     That is, the alignment slot  620  may be a space or a cutout in the woven fabric band  600  that will not hinder movement of an object or a portion of the object from a first position to a second position. Although a rectangular alignment slot  620  is specifically shown in the figures, it is contemplated that the alignment slot  620  may be placed in any position on the woven fabric band  600  and have a variety of configurations. For example, the alignment slot  620  may be circular, square or other such shape. 
       FIG.  6 B  illustrates an object  630  that is aligned with the woven fabric band  600  and the alignment slot  620  according to one or more embodiments of the present disclosure. In certain embodiments, to assist with the alignment, the woven fabric band  600  and the object  630  may be placed in a mold (not shown). As shown in  FIG.  6 B , the distal end  610  of the woven fabric band  600  may be formed, cut or otherwise manipulated to mirror a general shape of the object  630 . 
     In some embodiments, a plurality of threads may be exposed from the distal end  610  of the woven fabric band  600 . In such embodiments, the plurality of threads may be at least partially aligned with the object  630 . Thus, as the woven fabric band  600  is cut, formed or otherwise manipulated into a desired shape, the plurality of threads may be exposed. Although a specific object  630  is shown, it is contemplated that the object  630  may be any number of securement mechanisms used to secure the woven fabric band  600  to another object. Non-limiting examples include clasps, hooks, and other such fasteners. 
       FIG.  6 C  illustrates a woven fabric band  600  that is coupled to an object  630 . As shown in  FIG.  6 C , the object  630  is coupled to the woven fabric band  600  using a plurality of threads  640 . As also shown in  FIG.  6 C , the woven fabric band  600  may be structured in such a way as to enable the object  630  to be flush or substantially flush against the distal end  610  of the woven fabric band  600 . When the object  630  is positioned at the distal end  610  of the woven fabric band  600 , the plurality of threads  640  may be wound, stitched or otherwise placed around at least a portion of the object  630  to secure the object  630  to the distal end  610  of the woven fabric band  600 . The stitching process may be performed by hand or by a machine. 
       FIG.  6 D  illustrates a woven fabric band  600  that is coupled to an object  630  using a plurality of threads  640 . However, in the embodiment illustrated in  FIG.  6 D , the plurality of threads  640  have been subjected to a heating process. The heating process subjects the plurality of threads to a reflow process which subsequently causes the plurality of threads  640  to increase in tensile strength. The reflow process may also decreases the overall width (or other dimension) of one or more threads in the plurality of threads  640 . 
     For example, when comparing the plurality of threads  640  of  FIG.  6 C  to the plurality of threads  640  of  FIG.  6 D , the plurality of threads  640  in  FIG.  6 D  have a smaller diameter. The smaller diameter may enable the object  630  to be securely coupled to the woven fabric band  600 . In addition, a second object (not shown) may be coupled to the object  630  to provide additional functionality to the object  630  and also to hide the plurality of threads  640  from view. In embodiments, the second object may be a clasp or other attachment mechanism that interacts with the object  630 . 
     As with the woven fabric band  100  described above, the woven fabric band  600  comprises an inner layer and an outer layer. The outer layer of the woven fabric band  600  may have a first temperature melting point while the inner layer may have a second temperature melting point that is lower than the first temperature melting point. As the plurality of threads  640  are part of the inner layer, the plurality of threads  640  also have the first temperature melting point. Thus, when the woven fabric band is exposed to a heating process having a temperature equivalent to the first temperature melting point, the plurality of threads  640  undergo the reflow process while the outer layer remains unchanged. 
       FIG.  7    illustrates a cross-sectional view of a woven fabric band  600  according to one or more embodiments of the present disclosure. As shown in  FIG.  7   , the woven fabric band  600  is comprised of an outer layer  710  and an inner layer  720 . In certain embodiments, the outer layer  710  may be woven material of a first type and the inner layer  720  may be a woven material of a second, different type. In other embodiments, the outer layer  710  and the inner layer  720  may be the same type of woven material but have different temperatures melting points. For example, the temperature melting point of the outer layer  710  may be 220 degrees Celsius while the temperature melting point of the inner layer  720  may be 110 degrees Celsius. In still yet other embodiments, the outer layer  710  may be made of a first material and have a first temperature melting point (e.g., 220 degrees Celsius) and the inner layer  720  may be made of a second material and have a second temperature melting point (e.g., 110 degrees Celsius). 
     In certain embodiments, the outer layer  710  may be a sheath that has a cross-hatch configuration. In such embodiments, the inner layer  720  may be comprised of another material or fiber. As shown in  FIG.  7   , the outer layer  710  may surround the inner layer  720 . It is also contemplated that the outer layer  710  may be configured to removably slide over the inner layer  720  prior to applying the heating process to a distal end of the woven fabric band  600 . 
     As discussed above, one or more embodiments provide that the inner layer  720  has a lower temperature melting point than the outer layer  710 . As a result, when heat is applied to the woven fabric band  600 , the inner layer  720  may melt or become more malleable. As such, the inner layer  720  may be manipulated (e.g., using a mold or other such form factor mechanism) to take a desired form or shape. As the inner layer  720  melts and is manipulated into a new shape, one or more embodiments provide that the outer layer  710  conforms to the new shape of the inner layer  720 . However, because the outer layer  710  has a higher temperature melting point than the inner layer  720 , the outer layer  710  does not melt and may keep its original aesthetic look (i.e., the outer layer  710  is not damaged due to the melting process). 
     The process described above enables the inner layer  720  to take a variety of shapes and forms including, but not limited to three-dimensional shapes, logos, holes, protrusions, nubs, ridges, depressions, links, bosses and the like. As the inner layer  720  takes these various forms, the outer layer  710  conforms to the new shape of the inner layer  720 . In some embodiments, the outer layer  710  is flexible but durable. As such, the outer layer  710  may maintain its original aesthetic values. 
     As discussed above, a first portion of the woven fabric band  600  may be subjected to the heating process while a second, different portion of the woven fabric band  600  is not subjected to the heating process. For example, a plurality of threads may be placed on different portions of the woven fabric band  600  and then subjected to the heating process. The placement of the threads in this manner may enable a designer to create a number of different aesthetic looks for the woven fabric band  600 . For example, threads may be placed on the outer layer of the woven fabric band  600  in various configurations and designs. The individual threads or collections of threads may be subjected to a heating process which would cause the threads to melt and subsequently harden in the desired design or configuration. 
       FIG.  8    illustrates a cross-sectional view of the woven fabric band  600  with a plurality threads  800  extending therefrom according to one or more embodiments of the present disclosure. In certain embodiments, the plurality of threads  800  may be similar to the plurality of threads  640  ( FIG.  6 C ). The plurality of threads  800  may be part of the inner layer  720  of the woven fabric band  600 , an outer layer  710  of the woven fabric band or a combination thereof. In embodiments, the plurality of threads  800  may be exposed on a distal end of the woven fabric band  600  when a portion of the woven fabric band  600  is cut or otherwise manipulated into a desired shape or orientation. 
     Although a plurality of threads are specifically shown and described herein, it is contemplated that a long thread may be used to secure an object to the woven fabric band  600 . For example, a long thread may be interwoven with the woven fabric band  600 . In such embodiments, the long thread may have a length greater (e.g., two times greater) than a length of the woven fabric band  600 . A portion of the long thread may extend from the woven fabric band and be used to secure the object to a distal end or other area of the woven fabric band  600 . 
     In such embodiments, the long thread may have a temperature melting point that is lower than the rest of the woven fabric band  600 . Thus, when the heating process is applied, the long thread is the only material that is affected. In embodiments where the long thread is implemented, it is contemplated that the woven fabric band  600  may be comprised of a single layer. Although a singular long thread was used in the example above, it is contemplated that two or more long threads may be used to secure an object to the woven fabric band  600  such as described above. 
     Once the plurality of threads  800  have been exposed, the woven fabric band may be placed in a mold (not shown). The mold may be configured to receive an object, such as, for example, object  630  ( FIG.  6 C ) or object  150  ( FIG.  1 B ) that is to be coupled to the woven fabric band  600 . Once the woven fabric band  600  and the object  630  have been placed in the mold, the object  630  may be aligned with the woven fabric band in a desired orientation. The plurality of threads  800  may then be wrapped around at least a portion of the object  630 . A heating mechanism may then be used to melt the plurality of threads  800  surrounding the object. 
     In certain embodiments, the heating mechanism may be part of the mold. Thus, when the woven fabric band  600  and the object  630  are placed in the mold, the heating mechanism may be activated and cause the plurality of threads to reflow around the object  630 . In other embodiments, the heating mechanism may be part of the object  630 . In yet another embodiment, the object  630  may be pre-heated to a temperature that is equivalent to or greater than the temperature melting point of the plurality of threads  800 . Thus, as the plurality of threads  800  are wrapped around the object  630 , the reflow process may begin. 
     When a mold is used, the mold and/or the heating mechanism may include one or more overflow channels (not shown). In embodiments, the overflow channels are configured to enable the melted portions of the woven fabric band  600  to flow away from the woven fabric band  600 . Once the melted portions have moved away from the woven fabric band  600 , the melted material may be permanently removed (e.g., by cutting the melted material) and discarded. 
       FIG.  9    is a flow diagram that illustrates a method  900  for securing an object to a woven fabric band according to one or more embodiments of the present disclosure. In certain embodiments, the method  900  may be used to secure an object, such as, for example, object  630  ( FIG.  6 B ) to a woven fabric band, such as, for example woven fabric band  600  ( FIG.  6 A ). In certain embodiments, the woven fabric band may have multiple layers as shown and described above with reference to  FIG.  7   . 
     Method  900  begins when a plurality of threads of the woven fabric band are exposed  910 . In certain embodiments, the plurality of threads may be exposed by cutting, scarring, tearing, or machining at least a part of the woven fabric band. For example, it is contemplated that a woven fabric band may cut into smaller sub-bands. As a result of the woven fabric band being cut, the ends of the smaller sub-band may begin to fray, thereby exposing a plurality of threads. It is also contemplated that the inner layer of the woven fabric band may be manufactured to have a one or more threads extending therefrom. 
     Once the plurality of threads have been exposed, flow proceeds to operation  920  in which the woven fabric band is inserted into a mold. In certain embodiments, the mold may be configured to heat a region of the woven fabric band in order to cause the woven fabric band to take a particular shape. 
     Flow then proceeds to operation  930  and an object that is to be coupled to the woven fabric band is aligned with the woven fabric band. As briefly discussed above, the object may be placed in the mold along with the woven fabric band to help ensure that the alignment between the object and the woven fabric band is correct or that the object is in a desired orientation with respect to the woven fabric band. 
     Once the alignment has been verified, flow proceeds to operation  940  and the object is coupled to the woven fabric band. In certain embodiments, the plurality of exposed threads are used to stitch or otherwise secure the object to the woven fabric band (e.g., a distal end of the woven fabric band). It is contemplated that the stitching may be done by a machine or by hand. 
     Following the stitching process, flow proceeds to operation  950  in which heat is applied to the stitched plurality of threads. In certain embodiments, the plurality of threads are heated by one or more heating elements disposed in or on the mold. In embodiments where heating elements are disposed in or on the mold, the heating elements may be placed at various portions within the mold. As such, each heating element may be selectively activated in order to heat different portions of the woven fabric band. In some embodiments, the heating mechanisms may be placed on a top side and a bottom side of the mold. This may help ensure that the distal end of the woven fabric band (and the threads that are exposed from the distal end of the woven fabric band) are thoroughly exposed to the heating process. 
     In certain embodiments, the heating process may cause the thickness or the diameter of the plurality of threads to shrink. In another embodiment, the heating, melting and subsequent cooling process may cause the heated portion (once cooled) to be stronger and/or more rigid than the un-melted portions of the woven fabric band. Thus, the melted portion of the woven fabric band may be better suited to secure the object to the woven fabric band. 
     The description and illustration of one or more embodiments provided in this disclosure are not intended to limit or restrict the scope of the present disclosure as claimed. The embodiments, examples, and details provided in this disclosure are considered sufficient to convey possession and enable others to make and use the best mode of the claimed embodiments. Additionally, the claimed embodiments should not be construed as being limited to any embodiment, example, or detail provided above. Regardless of whether shown and described in combination or separately, the various features, including structural features and methodological features, are intended to be selectively included or omitted to produce an embodiment with a particular set of features. Having been provided with the description and illustration of the present application, one skilled in the art may envision variations, modifications, and alternate embodiments falling within the spirit of the broader aspects of the embodiments described herein that do not depart from the broader scope of the claimed embodiments.

Metadata:
Filing Date: 20141219
Publication Date: 20221206
Grant Date: 20221206
Priority Date: 20131220
Inventors: SIAHAAN, EDWARD
Weber, Douglas J.
CHEN, HSIANG HUNG
MATSUYUKI, NAOTO
HAMADA, YOJI
DABOV, TEODOR
MATTSON, WHITNEY D.
SU, Ying-liang
Assignee: APPLE INC
CPC Classifications: [{"code": "B32B7/023", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B2307/54", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B7/027", "inventive": true, "first": false, "tree": "[]"}, {"code": "B32B3/266", "inventive": true, "first": false, "tree": "[]"}, {"code": "B32B7/023", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B3/266", "inventive": true, "first": false, "tree": "[]"}, {"code": "B32B5/26", "inventive": true, "first": false, "tree": "[]"}, {"code": "B32B2250/20", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B7/023", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B2250/20", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B3/04", "inventive": true, "first": false, "tree": "[]"}, {"code": "B32B2307/54", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B3/04", "inventive": true, "first": false, "tree": "[]"}, {"code": "B32B5/26", "inventive": true, "first": false, "tree": "[]"}, {"code": "B32B2250/02", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B5/26", "inventive": true, "first": false, "tree": "[]"}, {"code": "B32B5/024", "inventive": true, "first": true, "tree": "[]"}, {"code": "B32B2250/02", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B2250/02", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B5/024", "inventive": true, "first": true, "tree": "[]"}, {"code": "Y10T428/24942", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B2250/20", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B3/266", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T428/24942", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29L2031/7282", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B7/027", "inventive": true, "first": false, "tree": "[]"}, {"code": "B32B2457/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B3/04", "inventive": true, "first": false, "tree": "[]"}, {"code": "B32B2307/54", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B2457/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B5/024", "inventive": true, "first": true, "tree": "[]"}, {"code": "B32B2457/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B7/027", "inventive": true, "first": false, "tree": "[]"}, {"code": "B32B3/266", "inventive": true, "first": false, "tree": "[]"}, {"code": "B32B5/26", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T428/24942", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B7/027", "inventive": true, "first": false, "tree": "[]"}, {"code": "B32B3/04", "inventive": true, "first": false, "tree": "[]"}, {"code": "B32B2457/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B7/023", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29L2031/7282", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B2250/20", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B2307/54", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B2250/02", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B5/024", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 53399088