Multi-Layered Woven Component

This application claims priority pursuant to 35 U.S.C. 119(a) to Chinese Application No. 202410404550.3, filed Apr. 3, 2024, which application is incorporated herein by reference in its entirety.

The invention generally relates to woven straps and fabrics, and more specifically, relates to a multi-layered woven component adapted to be used as a strap for a helmet or other similar articles.

Chin straps are an integral part of safety helmets and headgear designed to secure a helmet in place and provide additional protection against head injuries. The chin straps typically consist of a strap that wraps around a wearer's chin and is attached to the sides or rear of the helmet. The chin straps are made from materials that are soft yet durable, minimizing irritation or discomfort during prolonged wear. Typically, normal chin straps of safety helmets are made of single component yarn, having simple plain structures. These single component yarns have low moisture management performance. Therefore, the chin straps with poor moisture management may trap sweat against the wearer's skin, leading to discomfort, irritation, and chafing. This can be particularly problematic during physical activities or in hot and humid environments where sweating is common.

The inventors have identified numerous areas of improvement in the existing technologies and processes, which are the subjects of embodiments described herein. Through applied effort, ingenuity, and innovation, many of these deficiencies, challenges, and problems have been solved by developing solutions that are included in embodiments of the present disclosure, some examples of which are described in detail herein.

The following presents a summary of some example embodiments to provide a basic understanding of some aspects of the present disclosure. This summary is not an extensive overview and is intended to neither identify key or critical elements nor delineate the scope of such elements. It will also be appreciated that the scope of the disclosure encompasses many potential embodiments in addition to those here summarized, some of which will be further described in the detailed description that is presented later.

In accordance with various example embodiments of the present disclosure, a multi-layered woven component is disclosed. In some embodiments, the multi-layered woven component comprises a first side adapted to be in contact with a skin surface of a user, the first side comprises a plurality of yarns of a first type and a plurality of yarns of a second type. The plurality of yarns of the first type in the first side predominates the plurality of yarns of the second type in the first side. Further, a second side opposite the first side, the second side comprising at least a portion of the plurality of yarns of the second type. The plurality of yarns of the first type comprises hydrophobic yarns or yarns that are less hydrophilic than the plurality of yarns of the second type. The plurality of yarns of the second type comprises hydrophilic yarns or yarns that are less hydrophobic than the plurality of yarns of the first type. Further, the first side of the multi-layered woven component is woven with the second side of the multi-layered woven component to facilitate transfer of moisture from the first side of the multi-layered woven component to the second side of the multi-layered woven component.

In some embodiments, the second side comprises at least a portion of the plurality of yarns of the first type, and wherein the plurality of yarns of the second type in the second side predominates the plurality of yarns of the first type in the second side.

In some embodiments, the multi-layered woven component comprises a chin strap for a helmet or a headband for a helmet.

In some embodiments, the plurality of yarns of the first type and the plurality of yarns of the second type are woven as weft yarn and warp yarn in the first side and the second side of the multi-layered woven component. Further, at least one set of weft yarn are interconnected with at least two sets of the warp yarns to form the multi-layered woven component.

In some embodiments, the plurality of yarns of the first type and the plurality of yarns of the second type create a potential difference between the first side and the second side adapted to transfer the moisture received from the skin of the user from the first side to the second side of the multi-layered woven component.

In some embodiments, the second side of the multi-layered woven component is adapted to wick and evaporate the moisture received from the first side of the multi-layered woven component to keep the multi-layered woven component dry.

In some embodiments, the plurality of yarns of the first type and the plurality of yarns of the second type are woven as weft and warp yarn in a plurality of combinations, wherein the plurality of combinations comprises at least one of warp yarn of the first type, weft yarn of the first type, warp yarn of the second type, or weft yarn of the second type.

In some embodiments, the plurality of yarns of the first type are multifilament yarn, staple fiber yarn, low moisture regain yarn including polyester, nylon, polypropylene, and the staple fiber yarn includes cotton, viscos with hydrophobic treatment, or staple polyester yarn, etc.

In some embodiments, the plurality of yarns of the second type are multifilament yarn, staple fiber yarn, low moisture regain yarn with hydrophilic treatment including auxiliary finishing, profiled fiber and graft modification, wherein the graft modification including polyester, nylon, polypropylene, and the staple fiber yarn includes cotton, viscos.

In accordance with various other example embodiments of the present disclosure, a method of manufacturing an oven strap is disclosed. In some embodiments, the method comprises steps of weaving, a first side of the multi-layered woven component with a plurality of yarns of a first type and a plurality of yarns of a second type, wherein the plurality of yarns of the first type in the first side predominates the plurality of yarns of the second type in the first side; weaving, a second side of the multi-layered woven component with at least a portion of the plurality of yarns of the second type; wherein the plurality of yarns of the first type comprises hydrophobic yarns or yarns that are less hydrophilic than the plurality of yarns of the second type; wherein the plurality of yarns of the second type comprises hydrophilic yarns or yarns that are less hydrophobic than the plurality of yarns of the first type; wherein the first side of the multi-layered woven component is woven with the second side of the multi-layered woven component to facilitate transfer of moisture from the first side of the multi-layered woven component to the second side of the multi-layered woven component.

The above summary is provided merely for purposes of summarizing some example embodiments to provide a basic understanding of some aspects of the present disclosure. Accordingly, it will be appreciated that the above-described embodiments are merely examples and should not be construed to narrow the scope or spirit of the present disclosure in any way. It will be appreciated that the scope of the present disclosure encompasses many potential embodiments in addition to those here summarized, some of which will be further described below.

Some embodiments will now be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all, embodiments of the present disclosure are shown. Indeed, various embodiments may be embodied 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 satisfy applicable legal requirements.

The components illustrated in the figures represent components that may or may not be present in various embodiments of the present disclosure described herein such that embodiments may include fewer or more components than those shown in the figures while not departing from the scope of the present disclosure. Some components may be omitted from one or more figures or shown in dashed line for visibility of the underlying components.

As used herein, the term “comprising” means including but not limited to and should be interpreted in the manner it is typically used in the patent context. Use of broader terms such as comprises, includes, and having should be understood to provide support for narrower terms such as consisting of, consisting essentially of, and comprised substantially of.

The phrases “in various embodiments,” “in one embodiment,” “according to one embodiment,” “in some embodiments,” and the like generally mean that the particular feature, structure, or characteristic following the phrase may be included in at least one embodiment of the present disclosure and may be included in more than one embodiment of the present disclosure (importantly, such phrases do not necessarily refer to the same embodiment).

The word “example” or “exemplary” is used herein to mean “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other implementations.

If the specification states a component or feature “may,” “can,” “could,” “should,” “would,” “preferably,” “possibly,” “typically,” “optionally,” “for example,” “often,” or “might” (or other such language) be included or have a characteristic, that a specific component or feature is not required to be included or to have the characteristic. Such a component or feature may be optionally included in some embodiments, or it may be excluded.

Embodiments of the present disclosure will be described more fully hereinafter with reference to the accompanying drawings in which numerals represent like elements throughout the several figures, and in which example embodiments are shown. Embodiments of the claims may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. The examples set forth herein are non-limiting examples and are merely examples among other possible examples.

The present disclosure provides embodiments of a multi-layered woven component to dissipate the moisture from the skin surface of a wearer (e.g., face, scalp, etc.). Embodiments may be configured to have a first side adapted to be in contact with a skin surface of a user. The first side comprising a plurality of yarns of a first type and a plurality of yarns of a second type. Embodiments may be configured to have the plurality of yarns of the first type in the first side predominate the plurality of yarns of the second type in the first side. Embodiments may be configured to have a second side opposite the first side, the second side comprising at least a portion of the plurality of yarns of the second type. Embodiments may facilitate having the first side of the multi-layered woven component, woven with the second side of the multi-layered woven component to facilitate transfer of moisture from the first side of the multi-layered woven component to the second side of the multi-layered woven component.

illustrates a cross-sectional view of a multi-layered woven component, in accordance with an example embodiment of the present disclosure.

In some embodiments, the multi-layered woven componentmay have a first sideand a second side. In some embodiments, the first sideof the multi-layered woven componentmay be adapted to be in contact with the skin surface of a user. Further, the second sideof the multi-layered woven componentmay be opposite to the first sideof the multi-layered woven component. In some embodiments, the first sidemay further comprise a plurality of yarns of a first typeand a plurality of yarns of a second type. In some embodiments, the plurality of yarns of the first typein the first sidemay predominate the plurality of yarns of the second type.

As illustrated in, the plurality of yarns of the first typemay form small gaps that may have channels of the plurality of yarns of the second type. The plurality of yarns of the first typeand the plurality of yarns of the second typemay be arranged alternatively to one another. In some embodiments, the first sideof the multi-layered woven componentmay be arranged in such a way that the plurality of yarns of the first typemay predominate the second type. In some embodiments, the ratio between the plurality of yarns of the first typeand the second typemay alter between 3:1, 4:1, 2:1 etc. However, the plurality of yarns of the first typemay always be greater than the second type.

In some embodiments, the plurality of yarns of the first typemay comprise hydrophobic yarns. Further, the plurality of yarns of the second typemay comprise hydrophilic yarns or yarns that are less hydrophobic than the plurality of yarns of the first type. (For simplicity, yarns of the first type that are either hydrophilic or less hydrophobic than yarns of the second type will be referred to herein as simply “hydrophilic.”) In some embodiments, the plurality of yarns of the first typemay be a multifilament yarn, a staple fiber yarn, and a low moisture regain yarn. The first typemay be treated with a hydrophobic treatment to attain the hydrophobic properties. Thus, the hydrophobic property allows less absorption/transfer/retention of moisture in the plurality of first typeas compared to the plurality of the second type. Further, the first typemay be treated with an auxiliary finishing, a profiled fiber and a graft modification. In some embodiments, the graft modification includes polyester, nylon, polypropylene and the staple fiber yarn includes cotton and viscos.

In some embodiments, the second typemay be a multifilament yarn, a staple fiber yarn, and a low moisture regain yarn. The second typemay be treated with a hydrophilic treatment to attain the hydrophilic properties. Thus, the hydrophilic property allows more absorption/transfer/retention of moisture in the plurality of second type. Further, the second typemay be treated with an auxiliary finishing, a profiled fiber and a graft modification. In some embodiments, the graft modification includes polyester, nylon, polypropylene and the staple fiber yarn includes cotton and viscos. In some embodiments, the plurality of yarns of the second typecomprising hydrophilic yarns or yarns that are less hydrophobic than the plurality of yarns of the first typemay facilitate transfer of moisture from the first sideof the multi-layered woven component to the second side of the multi-layered woven component.

In some embodiments, the plurality of yarns of the first typeand the plurality of yarns of the second typemay facilitate creating a potential difference between the first sideof the multi-layered woven component and the second sideof the multi-layered woven component. Further, the created potential difference may enable moisture dropletsreceived from the skin of the user from the first sideto the second sideof the multi-layered woven component. The hydrophilic properties of the plurality of yarns of the second typecause the moisture dropletsto flow via the channels from the first sidetowards the second sidevia the plurality of yarns of second type.

In some embodiments, the second sidemay comprise at least the plurality of yarns of second type. The second typeis adapted to wick moisture from the first sideof the multi-layered woven component, evaporating the moisture received from the first sideof the multi-layered woven componentto the environment. In an exemplary embodiment, the second sidecomprises only the plurality of yarns of the second type. In another example embodiment, the second sidecomprises both the plurality of yarns of the first typeand the plurality of yarns of the second type, but the plurality of yarns of the second typepredominates the plurality of yarns of the first type.

illustrates a top view of a woven structurein a multi-layered woven component, in accordance with an example embodiment of the present disclosure.illustrates cross-sectional views of weft yarns and warp yarns in various example patterns of a multi-layered woven component, in accordance with an example embodiment of the present disclosure.are described in conjunction with.

In some embodiments, the plurality of yarns of the first typeand the plurality of yarns of the second typemay be woven as weft yarnsand warp yarnsrespectively in the first sideand the second sideof the multi-layered woven component. As shown in, the weft yarnsand the warp yarnsmay be woven in such a way that the weft yarnsare perpendicular to the warp yarns. The weft yarnsand the warp yarnsmay take turns to float of a cross pointon the first side. In some embodiments, the cross pointmay be the point where the weft yarnsmay cross the warp yarns. In an exemplary embodiment, the weft yarnsand the warp yarns, may be the hydrophobic yarn or hydrophilic yarn.

In some embodiments, the plurality of yarns of the first typeand the plurality of yarns of the second typemay be woven as the weft yarnsand the warp yarnsin a plurality of combinations.

illustrates cross-sectional views of a plurality of different weaving patterns of weft yarns and warp yarns in a multi-layered woven component in accordance with example embodiments of the present disclosure. In, weft yarns are illustrated as lines, while warp yarns are illustrated as circles (to indicate coming out of the page). In, hydrophobic yarns are illustrated as thin lines and circles, while hydrophilic yarns are illustrated as bold lines and circles. In, the first side (i.e., toward the skin surface) is the top side and the second side (i.e., toward the environment) is the bottom side. As seen in, the weaving patterns may comprise two or more layers of warp yarns with interwoven weft yarns. For example, weaving patterns,,,,, andcomprise three layers of warp yarns; weaving patternsandcomprise two layers of warp yarns; and weaving patternsandcomprise four layers of warp yarns. As seen in, the various weaving patterns result in the yarns of the first side (weft and/or warp) being both hydrophobic and hydrophilic, with the hydrophobic yarns predominating, while the yarns of the second side (weft and/or warp) are only hydrophilic.

In at least one example, the first weaving patterncomprises at least two layers of plurality of warp yarns of the first typeon the first side and at least one layer of warp yarns of the second typeon the second side. In the illustrated embodiment, the two layers of the warp yarns of the first typeare woven via a weft yarn of the first typein a zig-zag pattern. Further, the middle layer of the warp yarns of the first typeand the bottom layer of the warp yarns of the second typeare woven via a weft yarn of the second typein a zig-zag pattern. Further, all three layers of warp yarns are woven via the weft yarn of the second typein a zig-zag pattern.

In another example, the second weaving patterncomprises at least two layers of the plurality of the warp yarns of the first typeon the first side and at least one layer of the plurality of the warp yarns of the second typeon the second side of the multi-layered woven component. In the illustrated embodiment, the middle layer of the warp yarns of the first typeand the bottom layer of the warp yarn of second typeare woven via the weft yarn of the second typein a zig-zag pattern. Further, all three layers of warp yarns are woven via a weft yarn of the second typewoven in a zig-zag pattern.

In another example, the weaving patterncomprises at least a top layer of alternating the warp yarns of the first typeand the warp yarns of the second type, a middle layer of warp yarns of the first type, and a bottom layer of warp yarns of the second type. In the illustrated embodiment, the top and middle layers of warp yarns are woven via a weft yarn of the second typein a zig-zag pattern. Similarly, the middle and bottom layers of warp yarns are woven via a weft yarn of the second typein a zig-zag pattern.

In another example, the weaving patterncomprises at least a top layer of alternating the warp yarns of the first typeand the warp yarns of the second type, a middle layer of the warp yarns of the second type, and a bottom layer of the warp yarns of the second type. In the illustrated embodiment, the top and middle layers of warp yarns are woven via the weft yarn of the second typein a zig-zag pattern. Similarly, the middle and bottom layers of warp yarns are woven via a weft yarn of the second typewoven in a zig-zag pattern.

In another example, a weaving patterncomprises at least one layer of the plurality of the warp yarns of the first typeand the plurality of the warp yarns of the second typeon the first side, and at least one layer the plurality of the warp yarns of the second typeon the second side. In the illustrated embodiment, the two layers of warp yarns are woven via the weft yarn of the second type.

In another example, a weaving patterncomprises at least a top layer of alternating pairs of the warp yarns of the second typeand the warp yarns of the first typeand at least a bottom layer of warp yarns of the second type. In the illustrated embodiment, stacked pairs of warp yarns are woven via the weft yarn of the second type.

In another example, the weaving patterncomprises at least a top layer the warp yarns of the first typeand the warp yarns of the second type, a middle layer of the warp yarns of the second type, and a bottom layer of the warp yarns of the second type. In the illustrated embodiment, the layers of warp yarns are woven via the weft yarn of the second typein the eccentric zig-zag pattern shown. The hydrophilic weft yarn of the second typemay weave at least one layer having a pair of the warp yarns of the first typeand at least two pairs of the warp yarns of the second typein the zig-zag pattern. Further, the hydrophilic weft yarn of the second typemay weave at least two layers having a pair of the warp yarns of the second typein the zig-zag pattern. Further, the hydrophilic weft yarn of the second typemay weave at least one layer having a pair of the warp yarns of the first typeand at least two pairs of the warp yarns of the second typein the zig-zag pattern. Further, the hydrophilic weft yarn of the second typemay weave at least three pairs of the warp yarns of the second typein the zig-zag pattern. Further, the hydrophilic weft yarn of the second typemay weave at least one layer having a pair of the warp yarns of the first typeand at least one pair of the warp yarns of the second typein the zig-zag pattern. Further, the hydrophilic weft yarn of the second typemay weave at least three pairs of the warp yarns of the second typein the zig-zag pattern alternatively.

In another example, the weaving patterncomprises at least a top layer of the warp yarns of the first typeand the warp yarns of the second type, a middle layer of the warp yarns of the first type, and a bottom layer of the warp yarns of the second type. In the illustrated embodiment, the layers of warp yarns are woven via the weft yarn of the second typein the eccentric zig-zag pattern shown. The hydrophilic weft yarn of the second typein the zig-zag pattern to weave at least two layers having a plurality of pairs of the warp yarns of the first typeand a pair of the warp yarns of the second type. Further, the hydrophilic weft yarn of the second typein the zig-zag pattern to weave at least one layer having a pair of the warp yarns of the first typeand at least a layer having a pair of the warp yarns of the warp yarns of the second type. Further, the hydrophilic weft yarn of the second typemay weave at least two layers having a pair of the warp yarns of the first typeand at least a pair the warp yarns of the warp yarns of the second typein the zig-zag pattern. Further, the hydrophilic weft yarn of the second typemay weave at least a layer having a plurality of pairs of the warp yarns of the first typeand at least two pairs of the warp yarns of the second typein the zig-zag pattern. Further, the hydrophilic weft yarn of the second typemay weave at least two layers having a pair of the warp yarns of the first typein the zig-zag pattern. Further, the hydrophilic weft yarn of the second typemay weave at least a layer having a plurality of pairs of the warp yarns of the first typeand at least two pairs of the warp yarns of the second typein the zig-zag pattern alternatively.

In another example, the weaving patterncomprises at least a top layer of the warp yarns of the first typeand the warp yarns of the second type, a second layer of the warp yarns of the first type, a third layer of the warp yarns of the second type, and a bottom layer of the warp yarns of the second type. In the illustrated embodiment, the top three layers are woven by the weft yarn of the second typein a zig-zag pattern and the bottom three layers are woven by the weft yarn of the second typein a zig-zag pattern.

In another example, the weaving patterncomprises at least a top layer of the warp yarns of the first typeand the warp yarns of the second type, a second layer of the warp yarns of the first type, a third layer of the warp yarns of the second type, and a bottom layer of the warp yarns of the second type. In the illustrated embodiment, the top two layers are woven by the weft yarn of the second typein a zig-zag pattern and the bottom three layers are woven by the weft yarn of the second typein a zig-zag pattern.

illustrates a sectional top view of a portion of a multi-layered woven component, in accordance with an example embodiment of the present disclosure.illustrates a first side of the multi-layered woven componentwoven with an indicia, in accordance with an example embodiment of the present disclosure.illustrates schematic representation of the weft yarn and the warp yarn of the multi-layered woven component, in accordance with an example embodiment of the present disclosure.

In some embodiments, the multi-layered woven componentmay be divided into a plurality of sections as illustrated in. The multi-layered woven componentwith one endand another end, are woven via weft yarns and warp yarns. In some embodiments, the weft yarns and the warp yarns may be represented in cubes. The warp yarns on top of the cross point may be represented as an ‘X’and the weft yarns on top of the cross point may be represented as a blank cube, as illustrated in. in some embodiments, the cubesmay show the type of the yarn that floats on the surface at the cross point of warp yarns and weft yarns.

Further, the multi-layered woven componentmay be engraved with an indicia. The indiciamay be, for example, text, a logo, or a texture along the length of the multi-layered woven component, as illustrated in. In some embodiments, the indiciamay be the woven via the plurality of yarns of second type. Further, the indiciamay be fabricated using the second type yarns of polyester, nylon, polypropylene and the staple fiber yarn includes cotton, viscos. In an example embodiment, the first side of a multi-layered woven component and the second side of the multi-layered woven component defines a collective thickness with a minimum thickness of 0.1-1 mm and a maximum thickness of 12.7-20 mm.

illustrates a helmetinstalled with the multi-layered woven component, specifically a retention strap, in accordance with an example embodiment of the present disclosure.

In some embodiments, the multi-layered woven strapmay be coupled to the helmetas shown in. As illustrated in, the multi-layered woven strapmay be woven with the indicia(e.g., the text “H”) as described earlier in the first side. The multi-layered woven strapmay be incorporated into a plurality of different types of helmet assemblies. In some embodiments, the multi-layered woven strapmay further comprise a plurality of anchors, a lockand a chin support fixtureas illustrated in. In some embodiments, the multi-layered woven strapmay comprise a plurality of free ends. The plurality of free endsmay be coupled to the plurality of anchorsthat may be detachably coupled to the helmet. In some embodiments, the multi-layered woven strapmay comprise the lockto allow snap-fit arrangement for the user. The lockmay provide locking and unlocking of the multi-layered woven strap. Further, the lockallows quick release of the helmet. In some embodiments, the chin support fixturemay be integrated with the multi-layered woven strapto help retain and stabilize the helmeton the user head.