# US 2016/0258084 A1 · Woven materials and methods of forming woven materials

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- Number: US 2016/0258084 A1
- Document ID: US20160258084A1
- Status: Published application
- Kind: A1
- Application number: 14/790,123
- Filed: 2015-07-02
- Published: 2016-09-08
- Earliest claimed: 2015-03-06
- Assignees: Apple Inc.
- Applicants: Apple Inc.
- Inventors: Motohide Hatanaka; Ying-Liang Su; Yoji Hamada
- Web page: https://patentgrep.com/patent/US20160258084A1

## CPC

- D06C 7/00: Heating or cooling textile fabrics
- D03D 3/005: {Tapes or ribbons not otherwise provided for (D03D1/0005, D03D1/0011, D03D1/06, D03D1/08, D03D1/0094 take precedence)}
- D03D 11/02: Fabrics formed with pockets, tubes, loops, folds, tucks or flaps (fabrics consisting of a single tube D03D3/02)
- D03D 13/00: Woven fabrics characterised by the special disposition of the warp or weft threads, e.g. with curved weft threads, with discontinuous warp threads, with diagonal warp or weft
- D03D 13/004: {with weave pattern being non-standard or providing special effects}
- D06C: FINISHING, DRESSING, TENTERING OR STRETCHING TEXTILE FABRICS
- D03D: WOVEN FABRICS; METHODS OF WEAVING; LOOMS

## Abstract

Woven material and altering the weave pattern of the woven material. The woven material may comprise a first portion comprising a weave pattern formed by a plurality of warp threads and at least one weft thread woven between the plurality of warp threads. The first portion may have a first thickness. The woven material may also comprise a locally thinned portion positioned adjacent the first portion. The locally thinned portion may comprise an altered weave pattern, which may comprise the plurality of warp threads positioned on a single side of the at least one weft thread, and/or the at least one weft thread woven between the plurality of warp threads in the locally thinned portion is separated by a first distance. The first distance may be greater than a second distance positioned between the at least one weft thread woven between the plurality of warp threads in the first portion.

## Claims

### Claim 1

A woven material comprising:
a first portion comprising a weave pattern formed by a plurality of warp threads and at least one weft thread woven between the plurality of warp threads, the first portion having a first thickness; and
a locally thinned portion positioned adjacent the first portion, the locally thinned portion comprising an altered weave pattern comprising at least one of:
the plurality of warp threads positioned on a single side of the at least one weft thread; and
the at least one weft thread woven between the plurality of warp threads in the locally thinned portion is separated by a first distance, the first distance greater than a second distance positioned between the at least one weft thread woven between the plurality of warp threads in the first portion.

### Claim 2 (depends on 1)

The woven material of claim 1, wherein the plurality of warp threads in the altered weave pattern are positioned below the at least one weft thread in the locally thinned portion.

### Claim 3 (depends on 1)

The woven material of claim 1, wherein the locally thinned portion extends over a predetermined portion of a length of the woven material.

### Claim 4 (depends on 1)

The woven material of claim 1, wherein the locally thinned portion comprises a second thickness smaller than the first thickness of the first portion.

### Claim 5 (depends on 1)

The woven material of claim 1, wherein the plurality of warp threads alternate between being positioned above and below the at least one weft thread in the first portion and the locally thinned portion.

### Claim 6 (depends on 1)

The woven material of claim 1 further comprising a distinct portion positioned opposite the first portion, and separated from the first portion by the locally thinned portion, the distinct portion having the first thickness.

### Claim 7

A method of forming a woven material, the method comprising:
altering a weave pattern of the woven material comprising at least one weft thread, and a plurality of warp threads, the altering of the weave pattern comprising at least one of:
positioning the plurality of warp threads on a single side of the at least one weft thread; and
increasing a distance between the at least one weft thread woven between the plurality of warp threads; and
creating a locally thinned portion in the woven material at the altered weave pattern.

### Claim 8 (depends on 7)

The method of claim 7, wherein the positioning of the plurality of warp threads on the single side of the at least one weft thread further comprises positioning the plurality of warp threads below the at least one weft thread for a predetermined length of the woven material.

### Claim 9 (depends on 7)

The method of claim 7, wherein the increasing of the distance between the at least one weft thread woven between the plurality of warp threads further comprises continuously alternating the position of the plurality of warp threads above and below the weft thread in the altered weave pattern.

### Claim 10 (depends on 7)

The method of claim 7, wherein the created locally thinned portion in the woven material comprises a portion of the plurality of warp threads of the woven material positioned between the at least one weft thread having the increased distance.

### Claim 11 (depends on 7)

The method of claim 7 further comprising melting the woven material at the locally thinned portion of the woven material.

### Claim 12 (depends on 7)

The method of claim 7, wherein the creating of the locally thinned portion in the woven material further comprises reducing the thickness of the woven material in the locally thinned portion.

### Claim 13

A woven material comprising:
a first layer of a plurality of warp threads, the first layer forming a top surface;
a second layer of a plurality of warp threads positioned adjacent the first layer;
a third layer of a plurality of warp threads positioned adjacent the second layer;
a fourth layer of a plurality of warp threads positioned adjacent the third layer, the fourth layer forming a bottom surface;
at least one weft thread positioned between the plurality of warp threads over a length of:
the first layer;
the second layer;
the third layer; and
the fourth layer; and
at least one set of connection yarns woven through the at least one weft thread positioned between at least two distinct layers of the plurality of warp threads.

### Claim 14 (depends on 13)

The woven material of claim 13, wherein the at least one set of connection yarns further comprises:
a first set of connection yarns; and
a second set of connection yarns.

### Claim 15 (depends on 14)

The woven material of claim 14, wherein the first set of connection yarns is woven through the at least one weft thread positioned between the plurality of warp threads in:
the second layer; and
the third layer.

### Claim 16 (depends on 15)

The woven material of claim 15, wherein the second set of connection yarns is woven through the at least one weft thread positioned between the plurality of warp threads in:
one of:
the first layer, or
the second layer; and
the fourth layer.

### Claim 17 (depends on 16)

The woven material of claim 16, wherein in response to the second set of connection yarns woven through the at least one weft thread positioned between the plurality of warp threads in the second layer and the fourth layer, the first layer of the plurality of warp threads is disconnected from the remaining layers of the plurality of warp threads.

### Claim 18 (depends on 15)

The woven material of claim 15, wherein the second set of connection yarns is positioned between the at least one weft thread positioned between the plurality of warp threads in:
the second layer; and
the third layer.

### Claim 19 (depends on 14)

The woven material of claim 14, wherein the first set of connection yarns is positioned between the at least one weft thread positioned between the plurality of warp threads in:
the second layer; and
the third layer.

### Claim 20 (depends on 19)

The woven material of claim 19, wherein the second set of connection yarns is woven through the at least one weft thread positioned between the plurality of warp threads in:
one of:
the first layer, or
the second layer; and
the fourth layer.

### Claim 21 (depends on 13)

The woven material of claim 13, wherein the at least one set of connection yarns comprises:
a first connection yarn woven through the at least one weft thread positioned between the plurality of warp threads in:
the first layer and the fourth layer in a first portion of the woven material;
the second layer and the third layer in a second portion of the woven material positioned adjacent the first portion; and
the first layer and the fourth layer in a third portion of the woven material positioned adjacent the second portion; and
a second connection yarn woven through the at least one weft thread positioned between the plurality of warp threads in:
the first layer and the fourth layer in the first portion of the woven material;
the second layer and the third layer in the second portion of the woven material positioned adjacent the first portion; and
the first layer and the fourth layer in the third portion of the woven material positioned adjacent the second portion.

### Claim 22 (depends on 21)

The woven material of claim 21 further comprising a localized separation formed within the second layer of the plurality of warp threads and the third layer of the plurality of warp threads positioned in the second portion of the woven material.

### Claim 23

A wearable electronic device comprising:
a housing; and
a wearable band formed from a woven material coupled to the housing, the woven material comprising:
a first layer of a plurality of warp threads, the first layer forming a top surface;
a second layer of a plurality of warp threads positioned adjacent the first layer;
a third layer of a plurality of warp threads positioned adjacent the second layer;
a fourth layer of a plurality of warp threads positioned adjacent the third layer, the fourth layer forming a bottom surface;
at least one weft thread positioned between the plurality of warp threads over a length of:
the first layer;
the second layer;
the third layer; and
the fourth layer; and
a localized separation between two distinct layers of the plurality of warp threads in a portion of the woven material.

### Claim 24 (depends on 23)

The wearable electronic device of claim 23, wherein the woven material forming the wearable band further comprises:
a first connection yarn woven through the at least one weft thread positioned between the plurality of warp threads in:
the first layer and the fourth layer in a first portion of the woven material;
the second layer and the third layer in a second portion of the woven material positioned adjacent the first portion; and
the first layer and the fourth layer in a third portion of the woven material positioned adjacent the second portion; and
a second connection yarn woven through the at least one weft thread positioned between the plurality of warp threads in:
the first layer and the fourth layer in the first portion of the woven material;
the second layer and the third layer in the second portion of the woven material positioned adjacent the first portion; and
the first layer and the fourth layer in the third portion of the woven material positioned adjacent the second portion.

### Claim 25 (depends on 24)

The wearable electronic device of claim 24, wherein the localized separation is formed between the second layer of the plurality of warp threads and the third layer of the plurality of warp threads positioned in the second portion of the woven material.

### Claim 26 (depends on 23)

The wearable electronic device of claim 23, wherein the second layer of the plurality of warp threads further comprises:
a first warp thread woven through the at least one weft thread positioned between the second layer of the plurality of warp threads and the third layer of the plurality of warp threads for an altered weave portion of the woven material; and
a second warp thread positioned between the at least one weft thread positioned between the second layer of the plurality of warp threads and the first layer of the plurality of warp threads for the altered weave portion of the woven material.

### Claim 27 (depends on 26)

The wearable electronic device of claim 26, wherein the third layer of the plurality of warp threads further comprises:
the first warp thread woven through the at least one weft thread positioned between the second layer of the plurality of warp threads and the third layer of the plurality of warp threads for the altered weave portion of the woven material; and
the second warp thread positioned between the at least one weft thread positioned between the third layer of the plurality of warp threads and the fourth layer of the plurality of warp threads for the altered weave portion of the woven material.

### Claim 28 (depends on 27)

The wearable electronic device of claim 27, wherein the localized separation is formed in the altered weave portion of the woven material between:
the first warp thread of the second layer of the plurality of warp threads; and
the first warp thread of the third layer of the plurality of warp threads.

### Claim 29 (depends on 27)

The wearable electronic device of claim 27, wherein the plurality of warp threads of the first layer and the fourth layer are formed from a first material having a first melting temperature; and
wherein the plurality of warp threads of the second layer and the third layer are formed from a second material having a second melting temperature lower than the first melting temperature of the first material.

### Claim 30 (depends on 23)

The wearable electronic device of claim 23, wherein the at least one weft thread is formed within the woven material by:
a first weave pattern in portions of the woven material surrounding the localized separation; and
a second weave pattern in the portion of the woven material comprising the localized separation, the second weave pattern distinct from the first weave pattern.

### Claim 31 (depends on 30)

The wearable electronic device of claim 30, wherein the at least one weft thread woven using the first weave pattern is woven, in order, between:
the third layer of the plurality of warp threads;
the second layer of the plurality of warp threads;
the fourth layer of the plurality of warp threads; and
the first layer of the plurality of warp threads.

### Claim 32 (depends on 30)

The wearable electronic device of claim 30, wherein the at least one weft thread woven using the second weave pattern is woven, in order, between:
the fourth layer of the plurality of warp threads;
the third layer of the plurality of warp threads;
the second layer of the plurality of warp threads; and
the first layer of the plurality of warp threads.

### Claim 33

A method of forming a wearable band assembly formed from a woven material, the method comprising:
altering a weave pattern in a portion of the woven material forming the wearable band assembly, the woven material comprising:
four distinct layers of a plurality of warp threads; and
at least one weft thread woven through the plurality of warp threads for each of the four distinct layers; and
forming a localized separation between two distinct layers of the four distinct layers of the woven material, the localized separation formed between the two distinct layers of the woven material for receiving a pin.

### Claim 34 (depends on 33)

The method of claim 33 further comprising inserting the pin through the localized separation formed between the two distinct layers of the four distinct layers of the woven material.

### Claim 35 (depends on 34)

The method of claim 34 further comprising forming a pin aperture in a side of the woven material prior to the inserting of the pin through the localized separation formed between the two distinct layers of the woven material, the pin aperture aligned with the localized separation.

### Claim 36 (depends on 34)

The method of claim 34 further comprising processing a portion of the woven material positioned adjacent the localized separation formed between the two distinct layers of the woven material.

### Claim 37 (depends on 36)

The method of claim 36, wherein the processing of the portion of the woven material positioned directly adjacent the localized separation further comprises at least one of:
hot pressing the portion of the woven material positioned adjacent the localized separation;
pinching the portion of the woven material positioned adjacent the localized separation; and
laser cutting the portion of the woven material positioned adjacent the localized separation.

### Claim 38 (depends on 37)

The method of claim 37 further comprising at least one of:
sanding the laser cut portion of the woven material positioned adjacent the localized separation;
debossing the laser cut portion of the woven material positioned adjacent the localized separation; and
melting the laser cut portion of the woven material positioned adjacent the localized separation.

### Claim 39 (depends on 34)

The method of claim 34 further comprising coupling a connection device to the pin inserted through the localized separation formed between the two distinct layers of the woven material.

### Claim 40

A woven material forming at least two distinct wearable bands, the woven material comprising:
four distinct layers of a plurality of warp threads;
at least one weft thread positioned between the four distinct layers of the plurality of warp threads, the at least one weft thread woven through each of the four distinct layers of the plurality of warp threads twice between the plurality of warp thread alternating between being positioned above or below the at least one weft thread;
four distinct connection yarns woven through the at least one weft thread positioned between the plurality of warp threads; and
a localized separation formed between two distinct layers of the four distinct layers of the plurality of warp threads.

### Claim 41 (depends on 40)

The woven material of claim 40 further comprising:
a first wearable band region comprising a pin region;
a second wearable band region positioned adjacent the first wearable band region; and
a transition region formed between and integral with:
the first wearable band region; and
the second wearable band region.

### Claim 42 (depends on 41)

The woven material of claim 41, wherein the at least one weft thread is formed by:
a first weave pattern in:
the first wearable band region excluding the pin region;
the transition region; and
the second wearable band region; and
a second weave pattern in the pin region of the first wearable band region, the second weave pattern distinct from the first weave pattern.

### Claim 43 (depends on 42)

The woven material of claim 42, wherein the at least one weft thread woven using the first weave pattern is woven, in order, between:
the third layer of the plurality of warp threads;
the second layer of the plurality of warp threads;
the fourth layer of the plurality of warp threads; and
the first layer of the plurality of warp threads.

### Claim 44 (depends on 42)

The woven material of claim 42, wherein the at least one weft thread woven using the second weave pattern is woven, in order, between:
the fourth layer of the plurality of warp threads;
the third layer of the plurality of warp threads;
the second layer of the plurality of warp threads; and
the first layer of the plurality of warp threads.

### Claim 45 (depends on 41)

The woven material of claim 41, wherein the first layer of the plurality of warp threads and the fourth layer of the plurality of warp threads continuously alternate the position of the plurality of warp threads above and below the at least one weft thread.

### Claim 46 (depends on 45)

The woven material of claim 45, wherein the plurality of warp threads in the first layer and the fourth layer continuously alternate between being positioned above and below the at least one weft thread in:
the first band region excluding the pin region;
the transition region; and
the second band region.

### Claim 47 (depends on 46)

The woven material of claim 46, wherein the plurality of warp threads in the second layer are positioned above the at least one weft thread woven through the second layer of the plurality of warp threads in the pin region.

### Claim 48 (depends on 46)

The woven material of claim 46, wherein the plurality of warp threads in the third layer are positioned below the at least one weft thread woven through the third layer of the plurality of warp threads in the pin region.

### Claim 49 (depends on 41)

The woven material of claim 41, wherein the four distinct connection yarns comprises a first connection yarn woven through the at least one weft thread positioned within:
the first layer of the plurality of warp threads and the fourth layer of the plurality of warp threads in the first band region, excluding the pin region;
the third layer of the plurality of warp threads and the fourth layer of the plurality of warp threads in:
the pin region of the first band region; and
the transition region; and
the second layer of the plurality of warp threads and the third layer of the plurality of warp threads in the second band region.

### Claim 50 (depends on 49)

The woven material of claim 49, wherein the four distinct connection yarns comprises a second connection yarn woven through the at least one weft thread positioned within:
the first layer of the plurality of warp threads and the fourth layer of the plurality of warp threads in the first band region, excluding the pin region;
the first layer of the plurality of warp threads and the second layer of the plurality of warp threads in:
the pin region of the first band region; and
the transition region; and
the second layer of the plurality of warp threads and the third layer of the plurality of warp threads in the second band region.

### Claim 51 (depends on 50)

The woven material of claim 50, wherein the four distinct connection yarns comprises a third connection yarn woven through the at least one weft thread positioned within:
the second layer of the plurality of warp threads and the third layer of the plurality of warp threads in the first band region, excluding the pin region;
the first layer of the plurality of warp threads and the second layer of the plurality of warp threads in:
the pin region of the first band region; and
the transition region; and
the first layer of the plurality of warp threads and the fourth layer of the plurality of warp threads in the second band region.

### Claim 52 (depends on 51)

The woven material of claim 51, wherein the four distinct connection yarns comprises a fourth connection yarn woven through the at least one weft thread positioned within:
the second layer of the plurality of warp threads and the third layer of the plurality of warp threads in the first band region, excluding the pin region;
the third layer of the plurality of warp threads and the fourth layer of the plurality of warp threads in:
the pin region of the first band region; and
the transition region; and
the first layer of the plurality of warp threads and the fourth layer of the plurality of warp threads in the second band region.