ARTICLE STRAP WITH INTEGRATED RETAINING FEATURES

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No. 63/705,263 titled: Article Strap with Integrated Retaining Features, filed on Oct. 9, 2025. The entirety of the aforementioned application is incorporated by reference herein.

FIELD

The present disclosure generally relates to an article with a knitted strap with integrated retaining features.

Overview

In many consumer and commercial applications, such as backpacks, luggage, handbags, and utility straps, the incorporation of adjustable straps has become ubiquitous for securing and carrying loads. Adjustable straps typically comprise an elongated webbing or knitted band that is slideably engaged with a buckle or adjustment mechanism to vary the length of the strap. This adjustability allows users to customize the fit and function of the article for comfort, convenience, and security.

However, a common challenge with adjustable straps is the tendency of the buckle to slip along the strap during use. When the buckle does not maintain its position, the strap can unintentionally lengthen, resulting in a loose fit or compromised load security. This slippage can occur due to insufficient friction between the strap and the buckle, repeated movement, or the weight of the carried load. Such unwanted lengthening of the strap can diminish the functionality of the article, cause discomfort to the user, and require frequent readjustment.

BRIEF DESCRIPTION OF THE DRAWINGS

Non-limiting and non-exhaustive embodiments of the present invention are described with reference to the following figures, wherein like reference numerals refer to like parts throughout the various views unless otherwise specified.

FIG. 1 is a top-down isometric view of an article with knit straps with integrated retaining features according to aspects of this disclosure.

FIG. 2 is a rear view of the article of FIG. 1 according to aspects of this disclosure.

FIG. 3 is close-up view of one of the knit straps of FIGS. 1-2 according to aspects of this disclosure.

FIG. 4A an angled close-up view of one of the knit straps of FIGS. 1-2 and the knit strap of FIG. 3 according to aspects of the disclosure.

FIG. 4B is a side close-up view of one of the knit straps of FIGS. 1-2 and the knit straps of FIGS. 3 and 4A according to aspects of the disclosure.

FIG. 5 is a front close-up view of one of the knit straps of FIGS. 1-2 and the knit strap of FIGS. 2-4B according to aspects of the disclosure.

FIGS. 6A-6D show one example method of forming a knit loop according to aspects of this disclosure.

FIGS. 6E-6F are enlarged front and back views of the knit loop portion(s) in FIGS. 6A-6D.

FIG. 6G shows an example of a knit loop formed by a latch needle.

DETAILED DESCRIPTION

The detailed description set forth below in connection with the appended drawings is intended as a description of various configurations and is not intended to represent the only configurations in which the concepts described herein may be practiced. The detailed description includes specific details for the purpose of providing a thorough understanding of various concepts. However, it will be apparent to those skilled in the art that these concepts may be practiced without these specific details. In some instances, well known components are hidden from view to avoid obscuring such concepts. In addition, it is appreciated that the figures provided herewith are for explanation purposes to persons ordinarily skilled in the art and that the drawings are not necessarily drawn to scale.

I. Terminology

Reference throughout this specification to one aspect, an aspect, one example or an example means that a particular feature, structure or characteristic described in connection with the embodiment or example may be a feature included in at least example of the present invention. Thus, appearances of the phrases in one aspect, in an aspect, one example or an example in various places throughout this specification are not necessarily all referring to the same example. Furthermore, the particular features, structures or characteristics may be combined in any suitable combinations and/or sub-combinations in one or more or examples described herein.

Throughout the disclosure, the terms substantially or approximately may be used as a modifier for a geometric relationship between elements or for the shape of an element or component. While the terms substantially or approximately are not limited to a specific variation and may cover any variation that is understood by one of ordinary skill in the art to be an acceptable level of variation, some examples are provided as follows. In one example, the term substantially or approximately may include a variation of less than 10% of the dimension of the object or component. In another example, the term substantially or approximately may include a variation of less than 5% of the object or component. If the term substantially or approximately is used to define the angular relationship of one element to another element, one non-limiting example of the term substantially or approximately may include a variation of 5 degrees or less. These examples are not intended to be limiting and may be increased or decreased based on the understanding of acceptable limits to one of skill in the relevant art.

For purposes of the disclosure, directional terms are expressed generally with relation to a standard frame of reference when the aspects or articles described herein are in an in-use orientation. In some examples, the directional terms are expressed generally with relation to a left-hand coordinate system.

Terms such as a, an, and the, are not intended to refer to only a singular entity, but also include the general class of which a specific example may be used for illustration. The terms a, an, and the, may be used interchangeably with the term at least one. The phrases at least one of and comprises at least one of followed by a list refers to any one of the items in the list and any combination of two or more items in the list. All numerical ranges are inclusive of their endpoints and non-integer values between the endpoints unless otherwise stated.

The terms first, second, third, and fourth, among other numeric values, may be used in this disclosure. It will be understood that, unless otherwise noted, those terms are used in their relative sense only. In particular, certain components may be present in interchangeable and/or identical multiples (e.g., pairs). For these components, the designation of first, second, third, and/or fourth may be applied to the components merely as a matter of convenience in the description.

III. Detailed Examples

The detailed description and examples that follow, have been presented for purposes of illustration and description and are not intended to be exhaustive nor to limit the disclosure to the forms described. Numerous modifications are possible considering the teachings herein, including any combination of the different examples described herein. Some of those modifications have been discussed and others will be understood by those skilled in the art. The various aspects were chosen and described to best illustrate the principles of the present disclosure and various aspects as are suited to the particular use contemplated. The scope of the present disclosure is, of course, not limited to the examples or aspects set forth herein but can be employed in any number of applications and equivalent devices by those of ordinary skill in the art. Rather, it is hereby intended the scope be defined by the claims appended hereto.

FIGS. 1 and 2 show one example of an article 100. In some examples, the article may be a bag or backpack as shown; however, it is noted that aspects of this disclosure are applicable to other articles. Some non-limiting examples of articles include but are not limited to handbags, satchels, briefcases, purses, duffel bags or gym bags, luggage, cross-body bags or single strap bags, fanny packs or belt bags, belts, and/or any other article that may benefit from a strap and/or an adjustable strap. Additional examples include straps for storage or for strapping of articles. In one example, the article 100 may include a main body portion 150 for encloseably containing or for otherwise carrying or transporting items. In some examples, the main body portion may include top portion 150a and a bottom portion 150b with one or more openings 114 and/or one or more closure mechanisms, such as a zipper 116. The article 100 may further include a reinforcement or decorative strap or 112. In some examples, the article 100 may include a handle 110, which may for example be integrated with or formed as a single component with the handle 110.

In some non-limiting examples, the main body portion 150 of the 100 may for example be formed of fabric, leather, vinyl, plastic, and/or may be woven or knitted. In some examples any portion of or all of the main body portion 150 may be formed as a single continuous article and may be formed using a weft-knitting technique.

The woven article 100 may for example be knitted and include sections or knitted portions that are formed of knitted interlocking fiber loops, which may alternatively be referred to as stitches throughout this disclosure. In some examples, the stitches or loops or series of stitches or loops may be referred to throughout the disclosure as a knitted structure. The interlocking fiber loops may be formed of any yarn or thread formed of natural or synthetic materials or combinations thereof. Fibers include any one or a combination of natural or synthetic materials. Natural fibers include cotton, wool, alpaca, hemp, coconut fibers or silk, for example. Among the synthetic fibers are polymer-based fibers such as Nylon™, polyester, elastane or spandex, or Kevlar™, which may be produced as classic fibers, high-performance fibers, or technical fibers. Yarn and thread are terms for a structure of one or several fibers that is long in relation to its diameter. A fiber is a flexible structure that is rather thin in relation to its length. The terms yarn, thread, or textile may be used interchangeably throughout the disclosure.

The article 100 may for example be formed using an automated flat-knitting, fly-knitting and/or 3D knitting process via an automated or semi-automated knitting machine, that may employ any one or combination of weft-knitting and/or warp knitting to form the aforementioned interlocking fiber loops or stitches.

The stitches may for example be weft-knitted and/or warp-knitted. In weft-knitted fabrics and single-thread warp-knitted fabrics, the stitch formation may include at least one thread or yarn, with the thread running in a longitudinal direction of the product (at a right angle to the direction in which the product is made during the manufacturing process). In warp-knitted fabrics, the stitch formation may include at least one warp sheet (a plurality of so-called warps), with the stitch-forming threads running in a longitudinal direction (in the direction in which the product is made during the manufacturing process). Additional examples of methods of knitting and/or automated knitting are described in further detail with respect to FIGS. 6A-6D below.

As shown in FIGS. 1 and 2, the article 100 may include one or more straps 200. Each one of the straps may for example include a first strap portion 200a and/or a strap adjustment portion 200b. The first strap portion 200a may for example be a padded or otherwise may have foam or other known padded material contained therein to provide comfort to the wearer of the article 100. The one or more straps 200 may for example be formed using any of the manufacturing methods and/or materials mentioned herein.

The first strap portion(s) 200a may be connected to the article 100 at the top portion 150a at a first end and may be connected to or otherwise form a unitary or continuous structure with corresponding strap adjustment portion 200b at a second end thereof. The strap adjustment portion 200b may for example be connected to the bottom portion 150b of the article 100. It is noted that while the examples disclosed herein show the strap adjustment portion 200b closer to the bottom portion 150b than the top portion 150a of article 100, the disclosure is not limited to a particular location of the strap adjustment portion 200b. For example, the strap adjustment portion 200b may be closer to the top portion 150a or in some cases, the first strap portion 200a may be altogether omitted and the strap adjustment portion 200b may extend from the top portion 150a to the bottom portion 150b. Further, the strap adjustment portion 200b may be implemented into any article where adjustment of a strap length and/or an aesthetic quality is desired. As noted above, in some examples, the first strap portion 200a and the strap adjustment portion 200b may be connected via a sewn stitch or other connection method (e.g., melted, glued via an adhesive, ultrasonic welding or the like). In other examples, the strap adjustment portion 200b may be formed as a unitary structure or continuous structure with first strap portion 200a using the 3D knit techniques described herein or any known technique. As shown in FIG. 1, a stitch or other seam 230 may be implemented to contain the padding or other material within the first strap portion 200a while the first strap portion 200a and strap adjustment portion 200b are a unitary or continuous structure.

The strap adjustment portion 200b may for example be stitched or knitted using any of the 3D knitting or stitching techniques described herein or that are known in the art. The strap adjustment portion 200b may be formed to have an elongated strap or ribbon-like shape with a plurality of retention or retaining features thereon. In some examples, the retention or retaining features (which may alternatively be referred to as ridges or stepped portions) may for example comprise series of groves, channels, and/or protrusions (the aforementioned terms may be used interchangeably throughout the disclosure) that extend substantially perpendicular to the length of the strap adjustment portion 200b. For example, the retention or retaining features may include a convex or protrusion portion 264 (FIGS. 4A-5) and/or a series of concavities or channels 266. In some examples, the convex or protrusion portion(s) 264 may be substantially equally formed along the length of the strap adjustment portion 200b. In some examples, the convex or protrusion portion(s) 264 may be spaced a distance WW (FIG. 5) from one another. For example, a distance WW may be the distance from the center (e.g., the highest or tallest dimension) of a first convex or protrusion portion 264a to a second adjacent convex or protrusion portion 264b. In one example, the distance WW may be 3.0 millimeters (mm)-9.0 mm. In another example, the distance WW may be from 4.5 mm-7.0 mm. In yet another example, the distance WW may be from 5.5 mm-6.5 mm.

The spaces between aforementioned convex or protrusions portion(s) 264 may include concave portions, concavities, and/or channels (the aforementioned terms may be used interchangeably throughout the disclosure) 266.

The convex or protrusion portion(s) 264 and channels or concavities 266 may be formed to be adjacent one-another and may form a repeating pattern that runs the length of or partially the length of the strap adjustment portion 200b. For example, a distance WWW may be the distance along the strap length from the center (e.g., the highest or tallest dimension) of a first convex or protrusion portion 264a to a second the center of or lowest part of an adjacent channel or concavity 266. In one example, the distance WWW may be 1.5 millimeters (mm)-5 mm. In another example, the distance WWW may be from 2 mm-4 mm. In yet another example, the distance WWW may be from 2.5 mm-3.5 mm.

As shown in the Figures, the protrusion portions 264 and channels or concave portions 266 may form alternating regions of varying heights that may form the retaining features. A distance between the topmost surface of the protrusion portion(s) 264 and the lowest-most portion of the adjacent channel 266 may for example be 0.2 mm-1.5 mm. In another example, the aforementioned distance may be 0.5 mm-1.2 mm. In yet another example, the aforementioned distance may be 0.6 mm-0.9 mm.

The retaining features described herein may be fully integrated into the strap adjustment portion 200b so as to form a unitary or continuous structure. In other words, the convex or protrusion portions(s) 264 and/or the channels or concavities 262 may be formed as a unitary knit or stitched structure using the 3D knit methods described herein and/or using known knit methods. By providing integrated adjustment portions, no additional fabrics or other materials are required to be stitched or otherwise connected to the strap adjustment portion 200b, which may not only improve aesthetics and comfort, but may also improve efficiency of production and eliminate waste associated with creating such a structure from multiple components. Further, it is noted that while the retaining features that are shown in the Figures are a series of relatively linear or continuous ridges and/or grooves, any shape is contemplated by in this disclosure. For example, each groove and/or ridge could extend only partially across the width of the adjustment portion 200b and/or other shapes or designs may form the retaining features.

The series of repeating convex or protrusion portion(s) 264 and channels or concave portions 266 may for example engage with or otherwise prevent a buckle 232 from sliding along the strap (e.g., in directions SS or LL shown in FIG. 4A) until a user intentionally desires to slide the buckle along the strap adjustment portion 200b. The buckles 232 may for example have a first engagement region 232a, a second engagement region 232b, and/or a center engagement portion 231 (FIG. 3). In some examples, the buckle 232 may be a unitary structure configured to have portions of the strap adjustment portion 200b passed through openings formed between the center engagement portion 231 and the first engagement region 232a and second engagement region 232b. As shown in FIG. 4b, an end 271 of the strap adjustment portion 200b may be passed through the opening formed between the first engagement region 232a and the center engagement portion 231 and the opening formed between the second engagement region 232b and the center engagement portion 231 and may be connected to a looped connection portion 272 to affix the strap adjustment portion 200b to the buckle 232. As shown in FIG. 1, the strap adjustment portion 200b may then be passed through a second buckle 236 that is connected to the article 100 via an article connection features 238. The strap adjustment portion 200b may then be again passed through the opening between the second engagement region 232b and the center engagement portion 231 and again through the opening between the center engagement portion 231 and the first engagement region 232a so that a portion of the strap adjustment portion 200b contacts both the second engagement region 232b and the first engagement region 232a as well as another portion of the strap adjustment portion 200b that is looped around the center engagement portion 231 of the buckle 232. The friction between the aforementioned contact surfaces may prevent movement of the buckle in either of directions SS and/or LL (FIG. 4A) during use of the article while still allowing a user to adjust the length of the strap adjustment portion 200b (and thus the entire length of the straps(s) 200) by sliding the buckle 232 in either of direction SS (e.g., to shorten the length of the strap 200) or direction LL (to lengthen the length of the strap 200).

In some examples, the channels 266 and/or protrusion portion(s) 264 (which may herein be alternatively referred to as retaining features) may further prevent unintentional movement of buckle 232 along the strap adjustment portion 200b. Further, the retaining features described herein may provide a tactile sensation or otherwise provide a user with feedback or acknowledgement while sliding the buckle in direction SS and/or LL to indicate that the movement of the buckle 232 on the strap adjustment portion 200b is lengthening and/or shortening the strap 200. For example, as a user slides the buckle in either direction SS or LL, the first engagement region 232a and/or second engagement region 232b slide along and otherwise engage with the channels 266 and/or the protrusion portion(s) 264, which tactually and predictably increases and decreases the force required to move the buckle 232.

FIGS. 6A-6D show examples of how an automated knit, 3D knit and/or fly-knit fabric of any one or combination of the article and/or strap may be created. The article or portions of the article 100 and/or strap 200 may be formed by interlocking loops or stitches as shown in FIGS. 6A and 6C. The loops may be interlocked as the article is formed thus creating a portion of the article that expands as additional yarn is knitted thereon. For example, if the article or relevant portion of the article is weft-knitted, the article or portion of the article may be created by knitting one thread 601 from the left to the right (e.g., as shown in FIGS. 6B and 6D) using interlocking stitches as shown in FIGS. 6A and 6C. FIG. 6E is a close-up front view of an example of the front side 603 of article 100 (also referred to as the front loop fabric side) and FIG. 2F is a close-up back view (also referred to as the back loop fabric side) of a weft-knitted fabric. The legs 607a and 607b are covered on the back loop fabric side 607b, but not on the front loop fabric side 607a. It is noted that the aforementioned aspects are provided as examples only and may include or exclude features described herein. For example, filler yarn (not shown) may be provided either in-part or throughout the article. The filler yarn may be a length of a yarn placed between two wales 609 (FIG. 6F) in a longitudinal direction and may be held or otherwise inserted between transverse threads of other weave elements. Combining a filler yarn with other weave elements may be used to influence the properties of the weft-knitted fabric or to achieve various pattern effects. Elasticity or stretchability of the weft-knitted fabric in the direction of the wales may, for example, be reduced by the filler yarn.

Further, the article may be formed fully or at least in part by warp-knitting. Warp-knitting may utilize many threads from the top down and by interlocking the stitches of a thread with the stitches of neighboring threads. Depending on the desired pattern, the stitches of the neighboring threads are interlocked. Some examples of interlocking connections include but are not limited to pillar, tricot, 2×1 plain, satin, velvet, atlas, and twill.

The stitches described herein may be arranged above one another with joint binding sites, which as noted above may be referred to as wales. One example of a wale is shown as reference 609 in FIG. 6F. Wales may also be applicable to warp-knitting as well. Wales may run vertically through an article comprised thereof. Rows of stitches arranged next to one another, shown by way of example for a weft-knitted article with reference number 609 in FIG. 6D may be referred to as courses in both weft-knitted and warp-knitted articles. Generally, courses may run through the article in a lateral direction, for example.

The aforementioned knitted article or portion of a knitted article may be manufactured using an automated or semi-automated machine with a plurality of “needles.” In some aspects of the disclosure, the “needles” may comprise latch needles 630 (FIG. 6G), each of which comprise a pivotable latch 632 and a hook 634 at an end thereof. This latch 632 closes the hook 634 of the needle 630 such that a thread or yarn 602 may be pulled through a previously formed stitch 636. In one aspect, the needles 630 may be moveable individually, so that every single latch needle may be controlled to catch a thread for stitch formation.

In one aspect of the disclosure, the knitting machine may have two parallel rows of needles (e.g., needles 630). When looked at from the side, the needles of the two rows of needles may, for example, be opposite each other and angled relative to one another (e.g., at a right-angle). The use of two rows of needles allows for a one-layered or two-layered article to be simultaneously knitted. For example, a one-layered knitted fabric may be created when stitches generated on the first row of needles are intermeshed with stitches generated on the second row of needles. In another example, a two-layered knitted fabric may be created when stitches generated on the first row of needles are not, or are only selectively intermeshed with stitches generated on the second row of needles and/or if stitches generated on the first row of needles are merely intermeshed at an end of a tow-layered weft-knitted fabric.

Accordingly, an article as described herein may be at least partially manufactured using the aforementioned method and/or machine. If only one row of needles is used, a one-layered knit is created. If two rows of needles are used, stitches of both rows of needles may be connected consistently to each other so that a resulting knit comprises a single layer. If two rows of needles are used, and stitches of both rows of needles are not connected, or are only connected along certain lines, two layers are created, for example, to form a first layer and second layer in the knit.

Three-dimensional (3D) knit articles may also be manufactured via the aforementioned machine or method(s). In addition, 3D knit articles may be formed via weft-knitting machines and/or warp-knitting machines. 3D knitting or fly-knitting (the two terms may be used interchangeably herein) may be used to form articles or portions of articles that have spatial characteristics or structure. A three-dimensional weft-knitting or warp-knitting technique allows for spatial knitwear to be manufactured in a single process and without seams, cutting, or making-up into one piece.

The spatial structure described above may be formed by varying the number of stitches in the direction of the wales. The process of varying the number of stitches, which may otherwise be referred to as forming “partial courses” may be achieved by a mechanical process referred to as “needle parking.” When partial courses are formed, stitch formation temporarily occurs along only a partial width of the knitted article. The needles that are not involved in the stitch formation keep the half-finished stitches (“needle parking”) until weft-knitting occurs again at the same position.

The aspects described above may be used to knit an article that has different functional areas while maintaining its contours. The structures of knit articles may be adjusted to provide functional requirements in certain areas by the stitch pattern, the yarn, the needle size, the needle distance, or the tensile strain, which is subject to the yarn that is placed on the needles being selected accordingly. In some aspects of the disclosure, two or more knit layers may be combined and/or formed at once on a weft-knitting and/or warp-knitting machine with multiple rows of needles. In the case of two or more knit layers being combined, one or more layers may be formed in separate stages and then combined such as by stitching, gluing or otherwise adhering, welding (e.g., ultrasonic or chemical welding) and/or linking.

An alternative to two-layered knit articles may include spacer weft-knitted fabric or spacer warp-knitted fabric. In this example, a spacer yarn may be weft-knitted or warp-knitted loosely between two weft-knitted or warp-knitted layers, interconnecting the two layers, and simultaneously serving as a filler. The spacer yarn may be the same material or different from one or more of the layers themselves. Spacer weft-knitted fabrics or spacer warp-knitted fabrics may also be referred to herein as three-dimensional (3D) articles, but may be different from the aforementioned 3D weft-knitted fabrics or 3D warp-knitted fabrics or articles.

Additional aspects of the disclosure are described in the clauses that follow:

Clause 1. An article comprising: an elongated knit strap having a length and connected to the article; an adjustment buckle slideably disposed on the strap; and a plurality of knit retaining features that extend substantially perpendicular to the length of the strap, wherein the plurality of retaining features are configured to retainably engage with at least a first portion of the buckle and prevent the buckle from sliding along the length of the strap.

Clause 2. The article of clause 1, wherein the strap and the knit retaining features form a continuous knit structure.

Clause 3. The article of any of the preceding clauses, wherein each of the plurality of retaining features comprise one of a groove, channel, concavity, protrusion, stepped portion, convex shape, or ridge.

Clause 4. The article of any of the preceding clauses, wherein the plurality of retaining features comprise a repeating series of grooves that are adjacent to respective channels.

Clause 5. The article of any of the preceding clauses, wherein the buckle comprises a first opening and a second opening and a first engagement region corresponding with the first opening and a buckle corresponding with the second opening.

Clause 6. The article of any of the preceding clauses, wherein a first knit retaining feature of the knit retaining features is configured to engage with the first engagement region and a second knit retaining feature of the knit retaining features is configured to engage with the second engagement region.

Clause 7. The article of any of the preceding clauses, wherein the strap is connected to the article at a first end and is connected to the buckle at a second end.

Clause 8. The article of any of the preceding clauses, wherein the retaining features comprise a plurality of ridges, wherein a distance from the center of a first ridge to the center of a second ridge is 3.0 millimeters (mm)-9.0 mm.

Clause 9. The article of any of the preceding clauses, wherein the retaining features comprise a plurality of ridges and adjacent grooves, wherein a distance from the topmost surface of a first ridge of the plurality of ridges and the bottom most surface of an adjacent first groove of the plurality of grooves is 0.2 mm-1.5 mm.

This written description uses examples to disclose aspects of the invention, including the preferred embodiments, and also to enable any person skilled in the art to practice the aspects thereof, including making and using any devices or systems and performing any incorporated methods. The patentable scope of these aspects is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims. Aspects from the various embodiments described, as well as other known equivalents for each such aspect, can be mixed and matched by one of ordinary skill in the art to construct additional embodiments and techniques in accordance with principles of this application.