Woven article with integrated reinforcement zones and straps

Abstract

There is disclosed a woven textile article wherein the article comprises a plurality of reinforcement zones extending at least a portion of the width and / or length of the article, wherein the weft and / or warp of the reinforcement zones have at least one selected from i) a higher yarn tensile strength compared to the adjacent areas outside the reinforcement zones, and ii) a higher yarn density compared to adjacent areas of the reinforcement zones, wherein at least a one edge of the article is a tuck-in selvedge, and wherein straps are attached to at least one selected from i) the reinforcement zones, and ii) the at least one tuck-in selvedge edge. Advantages include that the woven article, when used as a transfer sheet for a patient, gives a higher comfort compared to a transfer sheet with added reinforcements.

Description

[0001] WOVEN ARTICLE WITH INTEGRATED REINFORCEMENT ZONES AND STRAPS

[0002] Technical field

[0003] The present invention relates to a woven article with straps and woven reinforcements, such as for instance a transfer bed sheet or a sling for patients . The present invention further relates to a method for manufacturing such an article .

[0004] Background

[0005] EP 2 641 578 discloses a patient transfer sheet acting as a combined sling and bed cover and includes a substantially rectangular sheet portion of a size to fit over a standard bed mattress and to which are attached a plurality of straps for coupling to a hoist . The patient transfer sheet is preferably made of a single-layered material which is breathable, strong and soft . The patient transfer sheet can act as a sling for transportation / repositioning of a patient as well as a replacement bed covering to replace conventional bed linen. The patient can Thus, be transported onto a bed without needing to remove the patient from the sling.

[0006] A problem with such patient transfer sheets is that reinforcements are needed to make the sheet sufficiently strong so that the patient can be lifted with a hoist . Such reinforcements are in the prior art sewn into the sheet and those added reinforcements are irritating for the patient when the patient is on the sheet . The added reinforcements give a discomfort to the patient .

[0007] One solution to this in the prior art is to use a very strong fabric in the sheet and to attach straps to the edges of the sheet without any particular reinforcements in the fabric ofthe sheet . Such fabric is however expensive, since stronger and more expensive materials have to be used.

[0008] Furthermore, US 5, 240, 756 A discloses a tarpaulin for covering and securing a load on a transport means, comprising a woven fabric with integrally woven reinforcement zones . These zones are formed by weaving areas with weft yarns of a greater thickness and tensile strength, which alternate with weaker areas in the fabric . Fastening means are attached to these reinforced zones, allowing the load-bearing strains to be exerted on the strongest parts of the tarpaulin.

[0009] Thus, there is still need for an improvement regarding a patient transfer sheet .

[0010] Summary

[0011] It is an obj ect of the present invention to alleviate at least some of the disadvantages in the prior art and provide a woven article with straps, such as woven articles with integrated reinforcement zones in the weft and / or warp .

[0012] In a first aspect there is provided a woven textile article with a length and a width and the textile article comprising warp and weft, wherein the article comprises a plurality of reinforcement zones extending across at least a portion of the width and / or length of the article, wherein the weft and / or warp of the reinforcement zones have at least one selected from i) a higher yarn tensile strength compared to adj acent areas outside the reinforcement zones, and ii) a higher yarn density compared to adj acent areas outside the reinforcement zones, wherein at least a one edge of the article is a tuck-in selvedge, and wherein straps areattached to at least one selected from i) the reinforcement zones, and ii) the at least one tuck-in selvedge edge .

[0013] In a second aspect there is provided a method for producing a woven textile article with a length and a width and comprising warp and weft, the method comprising the steps of : (a) providing a warp and weaving the weft, whereby reinforcement zones are provided by weaving parts of the weft and / or warp with a yarn with higher tensile strength and / or weaving parts of the weft and / or warp with a higher yarn density to obtain a higher tensile strength compared to adj acent areas outside the reinforcement zones, wherein the weaving step forms a tuck-in selvedge on at least one edge of the article,

[0014] (b) attaching straps to at least one selected from i) the reinforcement zones and ii) the at least one tuck-in selvedge edge .

[0015] An advantage is that the woven article, when used as a transfer sheet for a patient gives a higher comfort compared to a transfer sheet with added reinforcements . Unlike solutions in the prior art, this invention integrates reinforcement zones directly into the fabric during weaving, improving patient comfort and reducing manufacturing complexity .

[0016] The woven article is further inexpensive to manufacture and is suitable for large scale manufacturing.

[0017] Brief description of the drawings

[0018] Aspects and embodiments will be described with reference to the following drawings in whichFigure 1 shows a schematic representation of the textile article according to an embodiment of the invention. The length is shown along the horizontal axis in figure 1 and the width is shown along the vertical axis in figure 1. Thus, the warp is parallel to the length and the weft is parallel to the width. There are schematically shown the location of a number of reinforcement zones extending over the width of the article and represented by dashed lines . The straps are not shown in this representation.

[0019] Figure 2 shows a schematic representation of the textile article according to an embodiment of the invention. The length is shown along the horizontal axis in figure 2 and the width is shown along the vertical axis in figure 2. Thus, the warp is parallel to the length and the weft is parallel to the width. There are schematically shown the location of a number of reinforcement zones extending at least partially across width and / or length of the article and represented by dashed lines . The straps are not shown in this representation .

[0020] Figure 3 shows a schematic representation of the textile article according to an embodiment of the invention. The length is shown along the horizontal axis in figure 3 and the width is shown along the vertical axis in figure 3. Thus, the warp is parallel to the length and the weft is parallel to the width. There are schematically shown the location of a number of reinforcement zones extending across the width of the article and represented by dashed lines . The straps are attached to the reinforcement zones .

[0021] Figure 4 shows a schematic representation of the textile article according to an embodiment of the invention. Thelength is shown along the horizontal axis in figure 4 and the width is shown along the vertical axis in figure 4. Thus, the warp is parallel to the length and the weft is parallel to the width. There are schematically shown the location of a number of reinforcement zones extending at least partially across the width and length of the article and represented by dashed lines . A number of straps are attached to various reinforcement zones .

[0022] Figure 5 shows a schematic representation of the textile article according to an embodiment of the invention. The length is shown along the horizontal axis in figure 5 and the width is shown along the vertical axis in figure 5. Thus, the warp is parallel to the length and the weft is parallel to the width. There are schematically shown the location of a number of reinforcement zones extending at least partially across the width and length of the article and represented by dashed lines . A number of straps are attached to at least one edge of the article manufactured using a tuck-in device .

[0023] Figures 6a and 6b show schematic representations of the attachment of a strap to a reinforcement zone according to an embodiment of the invention. There are schematically shown the location of reinforcement zones across the article represented by thick dashed lines .

[0024] These drawings serve only as a representation and are not in any way limiting of the embodiments of the invention.

[0025] Detailed description

[0026] Before the invention is disclosed and described in detail, it is to be understood that this invention is not limited to particular compounds, configurations, method steps,substrates, and materials disclosed herein as such compounds, configurations, method steps, substrates, and materials may vary somewhat . It is also to be understood that the terminology employed herein is used for the purpose of describing particular embodiments only and is not intended to be limiting since the scope of the present invention is limited only by the appended claims .

[0027] It must be noted that, as used in this specification and the appended claims, the singular forms "a", "an" and "the" include plural referents unless the context clearly dictates otherwise .

[0028] If nothing else is defined, any terms and scientific terminology used herein are intended to have the meanings commonly understood by those of skill in the art to which this invention pertains .

[0029] In the first aspect there is provided a woven textile article with a length and a width and the textile article comprising warp and weft, wherein the article comprises a plurality of reinforcement zones extending across at least a portion of the width and / or length of the article, wherein the weft and / or the warp of the reinforcement zones have at least one selected from i) a higher yarn tensile strength compared to adj acent areas outside the reinforcement zones, and ii) a higher yarn density compared to adj acent areas outside the reinforcement zones, wherein at least a one edge of the article is at least partially manufactured using a tuck-in device (i . e . , wherein at least a one edge of the article is a tuck-in selvedge) , and wherein straps are attached to at least one selected from i) the reinforcement zones, and ii) the at least one edge of the article manufactured using atuck-in device (i . e . , and ii) the at least one tuck-in selvedge edge) .

[0030] In an aspect, the reinforcement zones extend partially across the width and / or length of the article .

[0031] In a further aspect, the reinforcement zones extend across the entire width and / or length of the article .

[0032] In an aspect, the warp of the reinforcement zones has higher tensile strength compared to adj acent areas outside the reinforcement zones .

[0033] In a further aspect, the weft of the reinforcement zones has higher tensile strength compared to adj acent areas outside the reinforcement zones .

[0034] In an aspect, the reinforcement zones comprise yarn with a higher tensile strength compared to adj acent areas outside the reinforcement zones .

[0035] In another aspect, the reinforcement zones comprise a higher density of yarn compared to adj acent areas outside the reinforcement zones .

[0036] The weft extends along the width of the article and the warp extends along the warp of the article . The width is measured in the direction of the weft and the length is measured in the direction of the length. Longitudinal yarns are referred to as warp and are interlaced with weft during the weaving process .The reinforcement zones are woven across at least a portion of the width and / or length of the article . Compared to the woven material outside the reinforcement zones, the reinforcement zones are stronger, i . e . they have a higher tensile strength and can withstand a higher load compared to the woven material outside the reinforcement zones . This is achieved by using a stronger material in the yarn and / or a thicker yarn with higher tensile strength in the reinforcement zone . A different weaving technique with a denser weft and / or warp in the reinforcement zones can also contribute to an improved tensile strength in the reinforcement zones . The reinforcement zones may be a result of using different weaving techniques or patterns in the weft and / or warp of the weaved article to achieve higher tensile strength. In other words, the warp and / or weft of the reinforcement zones have at least one selected from i) a higher yarn tensile strength compared to the adj acent areas outside the reinforcement zones, and ii) a higher yarn density compared to adj acent areas outside the adj acent areas outside the reinforcement zones .

[0037] The term 'tensile strength' refers to a maximum load that a material can support without fracture when being stretched, divided by the original cross-sectional area of the material . In other words, it refers to the resistance of a material to breaking under tension. The higher tensile strength an article possesses, the higher load it can support without fracture when being stretched.

[0038] The stronger yarn for the reinforcement zones is expected to be more expensive compared to the yarn for the weft outside the reinforcement zones, however it should be kept in mind that the reinforcement zones constitute a fairly low area ofthe total area of the woven article . Due to the use of a less expensive material outside the reinforcement zones the total cost of the woven article can be kept low.

[0039] Straps may be attached to at least one selected from i) the reinforcement zones, such as at least a part of the reinforcement zones, and ii) the at least one edge of the article manufactured using tuck-in device . In one embodiment, straps are attached to at least one reinforcement zones . In a further embodiment, straps are attached to all reinforcement zones . The straps may be attached close to the edges of the woven article, such as to at least one edge of the article manufactured using a tuck-in device . The straps may have at least the same tensile strength as the reinforcement zones . The straps may act as an extension of the reinforcement zone .

[0040] The straps can be attached in different ways . The straps can be integrally weaved, glued, stitched, sewn, welded, taped, adhered using adhesive or otherwise, etc onto the reinforcement zones .

[0041] In an embodiment, the straps are attached to one side, such as a facing side (such as a side facing a patient) or a nonfacing side (such as a side not facing a patient) , or on both sides of the woven textile article .

[0042] The straps can be made of different material, including but not limited to textile, leather, synthetic resin etc . In one embodiment the straps are made of a textile material . A textile material includes various fiber-based materials, including fibers, yarns, filaments, threads, different fabric types, etc . Weaving is not the only manufacturing method forthe straps . Knitting and non-woven are also included for the straps .

[0043] In one embodiment the straps are attached by sewing.

[0044] The straps are intended to be attached to a hoist when the woven article is used as a transfer sheet or as a sling to lift a patient .

[0045] A skilled person will understand that the reinforcement zones may constitute different percentage of the surface of the woven article depending on the application of such zones . In one embodiment, the reinforcement zones constitute no more than 10% of the surface of the woven article . In another embodiment, the reinforcement zones constitute no more than 50%-l% of the surface of the woven article, such as no more than 30-5%, including no more than 20%-5% of the surface of the woven article . The area is measured when the woven article is placed on a flat surface in a non-stretched state but without any wrinkles or creases . It is an advantage that the use of more expensive yarn or more yarn for the reinforcement zone can be minimized.

[0046] In one embodiment, the woven article comprises four sides and where in at least two of the four sides have edges which are cut with ultrasound (i . e . , ultrasonic cutting) . The edges of the woven article can optionally be folded. The edges of the woven article can be cut using ultrasound (i . e . , ultrasonic cutting) . A skilled person will understand that ultrasonic cutting is advantageous at least in that it prevents fraying and enhances softness of the edges . It also simplifies the production. In one embodiment the edges parallel to the weft are cut, this can be done in a continuous production so thata long piece is woven, which is cut into suitable lengths . In another embodiment the edges parallel to the warp are cut, this can be combined with cutting the other edges or be performed independently. All cutting can be made by ultrasound and all cutting can also be combined with folding the edges .

[0047] In one embodiment, the woven article is a transfer sheet intended to be used for lifting a patient . Many different uses of the woven article are envisaged and this is one application .

[0048] When the woven article is used as a transfer sheet intended to be used for lifting a patient there is the advantage of improved comfort compared to reinforced transfer sheets according to the prior art . The reinforced transfer sheets according to the prior art have added reinforcements which can give discomfort to a patient on the transfer sheet . The woven article according to the present invention is more comfortable for a patient . When the reinforcement zones are not stretched, i . e . when the transfer sheet is like a normal sheet in a bed, the weft in the reinforcement zones and the weft outside the reinforcement zones feels about the same to a patient and thereby any discomfort to the patient is greatly reduced or non-existing.

[0049] In the second aspect there is provided a method for producing a woven textile article with a length and a width and comprising warp and weft, the method comprising the steps of : (a) providing a warp and weaving the weft, whereby reinforcement zones are provided by weaving parts of the weft and / or warp with a yarn with higher tensile strength and / or weaving parts of the weft and / or warp with a higher yarn density to obtain a higher tensile strength compared toadj acent areas outside the reinforcement zones, wherein at least one edge of the article is at least partially manufactured using a tuck-in device (i . e . , wherein the weaving step forms a tuck-in selvedge on at least one edge of the article) ,

[0050] (b) attaching straps to at least one selected from i) the reinforcement zones and ii) the at least one edge is at least partially manufactured using a tuck in device (i . e . , and ii) the at least one tuck-in selvedge edge) .

[0051] According to an aspect, the reinforcement zones are formed by varying the weaving pattern to increase yarn density in the reinforcement zones .

[0052] According to a further aspect, the reinforcement zones are formed in the warp .

[0053] According to another aspect, the reinforcement zones are formed in the weft .

[0054] According to an aspect, the method further comprises integrally weaving the at least one strap into at least one reinforcement zone . In a further aspect, the method comprises integrally weaving the straps into the reinforcement zones .

[0055] A longitudinal warp is provided as usual in weaving and then a weft is woven in the warp as known during the weaving.

[0056] Parts of the weft and / or warp are woven with a yarn with higher tensile strength and / or with higher yarn density so that reinforcement zones are created across at least a portion of the width and / or length of the woven article . The reinforcement zones are spaced apart in a suitable pattern. The reinforcement zones are in one embodiment spaced apartwith equal distance . In another embodiment the reinforcement zones are spaced apart with less distance in areas where the woven article has to carry higher load. The spacing of the reinforcement zones can be designed as needed depending on the desired strength and desired load bearing capacity of the woven article . Also the strength of the reinforcement zones is designed as needed depending on the desired strength and desired load bearing capacity of the woven article . If for instance the woven article is intended to be able so safely lift a patient with a weight of up to 100 kg in the straps, then a certain number of reinforcement zones and a certain strength of the reinforcement zones is needed. A skilled person is able to carry out such a calculation and testing in the light of this description.

[0057] In one embodiment, the straps are sewn onto at least a part of the at least one reinforcement zone, such as sewn onto at least a part of the reinforcement zones . In a further embodiment, the straps are sewn onto at least one edge of the woven article, which is manufactured using a tuck-in device .

[0058] In one embodiment the woven article is woven as a continuous woven article and subsequently cut into pieces . This is an efficient method for large scale manufacturing of woven articles . The continuous article can be cut into pieces of suitable length either directly after the weaving process or alternatively the continuous article can be stored and / or distributed and then cut into suitable pieces .

[0059] In one embodiment the edges along the warp, i . e . along the length of the woven article are folded. In another embodiment, the edges along the weft, i . e . along the width of the woven article are folded. In one embodiment this foldingis made continuously. Folding is advantageous in that it enhances durability of the article, such as at the edges of the article .

[0060] Weaving may be performed using for instance shuttle, circular, and narrow fabric machines .

[0061] Shuttle machines according to the present invention are those using a shuttle to insert weft yarn across warp threads, wherein the shuttle moves back and forth through the shed, creating the fabric one pass at a time .

[0062] Circular machines according to the present invention are those designed to weave fabric in a continuous, tubular shape . The weft yarn is inserted in a circular motion, allowing for fast and efficient production.

[0063] Narrow fabric machines according to the present invention are those built to weave fabrics that are typically 1 to 12 inches wide, like ribbons, trims, and tapes . They can handle finer yarns and intricate patterns, providing high precision for specialty textiles .

[0064] It is to be understood that the outer edges of the woven article may also be selvages running parallel to the warp yarns . The selvedge may be plain, tape, split, fused, leno, or tucked-in, as understood in the art .

[0065] A skilled person will understand that a tuck-in device refers to a device that is used to tuck and hold the cut ends into the fabric edge . A tuck-in device is a specialized attachment or mechanism on a loom that is used to manage the selvages (edges) of the woven fabric . Specifically, it "tucks in" theloose ends of the weft yarn at the edges of the fabric, ensuring that the selvages are neat, secure, and do not unravel . This is especially useful for fabrics where a clean and stable edge is required, such as high-quality textiles . When the shuttle (or another weft-insertion device) moves back and forth, the weft yarn is cut at the edges . The tuck-in device ensures these cut ends are inserted back into the fabric ' s structure rather than left loose . This makes the selvages strong, which is useful when straps are attached to the edges made with a tuck-in device . In tucked-in edges, the fringed edges of the weft yarns are woven back into the body of the fabric using a special tuck-in mechanism. As a result, the weft and / or warp density may be substantially increased in the edge area .

[0066] Tuck-in devices are common for instance in shuttleless looms, such as rapier, proj ectile, and air-j et looms, where the weft is not carried in a continuous loop .

[0067] In one embodiment the woven article is cut with ultrasonic cutting. Ultrasonic cutting has the advantage that the cut is sealed so that the edges of the woven article are preserved. Further the edges become soft when touching them. This is an advantage of ultrasonic cutting over for instance heat cutting, which typically gives edges which feels hard when touching them. The ultrasonic cutting eliminates or decreases the need of sewing the edges . The ultrasonic cutting can advantageously be combined with the weaving of a continuous woven article and which subsequently is cut into pieces . This will give an efficient manufacturing process .

Claims

Claims1. A woven textile article with a length and a width and the woven article comprising warp and weft, wherein the article comprises a plurality of reinforcement zones extending across at least a portion of the width and / or length of the article, wherein the weft and / or warp of the reinforcement zones have at least one selected from i) a higher yarn tensile strength compared to adj acent areas outside the reinforcement zones, and ii) a higher yarn density compared to adj acent areas outside the reinforcement zones, wherein at least a one edge of the article is a tuck-in selvedge, and wherein straps are attached to at least one selected from i) the reinforcement zones, and ii) the at least one tuck-in selvedge edge .

2. The woven article according to claim 1, wherein the straps are attached to the reinforcement zones .

3. The woven article according to claims 1 or 2, wherein the straps are made of a textile material .

4. The woven article according to any one of claims 1-3, wherein the straps are attached by a method selected from the group consisting of sewing, welding, stitching, gluing, and taping .

5. The woven article according to any one of claims 1-4, wherein the reinforcement zones constitute no more than 10% of the surface of the woven article .

6. The woven article according to any one of claims 1-5, wherein the woven article comprises four sides and wherein atleast two of the four sides have edges which are cut with ultrasonic cutting.

7. The woven article according to any one of claims 1-6, wherein the woven article is a transfer sheet intended to be used for lifting a patient .

8. The woven article according to any one of claims 1-7, wherein the warp of the reinforcement zones has higher tensile strength compared to adj acent areas outside the reinforcement zones .

9. The woven article according to any one of claims 1-8, wherein the weft of the reinforcement zones has higher tensile strength compared to adj acent areas outside the reinforcement zones .

10. The woven article according to any one of claims 1- 9, wherein the reinforcement zones comprise yarn with a higher tensile strength compared to adj acent areas outside the reinforcement zones .

11. The woven article according to any one of claims 1- 10, wherein the reinforcement zones comprise a higher density of yarn compared to adj acent areas outside the reinforcement zones .

12. The woven article according to any one of claims 1- 11, wherein the reinforcement zones extend partially across the width and / or length of the article .

13. The woven article according to any one of claims 1- 12, wherein the straps are integrally woven into the reinforcement zones .

14. The woven article according to any one of claims 1- 13, wherein the reinforcement zones are created using different weaving techniques or patterns to achieve higher tensile strength.

15. A method for producing a woven textile article with a length and a width and comprising warp and weft, the method comprising the steps of :(a) providing a warp and weaving the weft, whereby reinforcement zones are provided by weaving parts of the weft and / or warp with a yarn with higher tensile strength and / or weaving parts of the weft and / or warp with a higher yarn density to obtain a higher tensile strength compared to adj acent areas outside the reinforcement zones, wherein the weaving step forms a tuck-in selvedge on at least one edge of the article,(b) attaching straps to at least one selected from i) the reinforcement zones and ii) the at least one tuck-in selvedge edge .

16. The method according to claim 15, wherein the reinforcement zones are formed by varying the weaving pattern to increase yarn density in the reinforcement zones .

17. The method according to any one of claims 15 or 16, wherein the reinforcement zones are formed in the warp .

18. The method according to any one of claims 15 or 16, wherein the reinforcement zones are formed in the weft .

19. The method according to any one of claims 15-18, further comprising integrally weaving the straps into the reinforcement zones .

20. The method according to any one of claims 15-19, wherein the straps are sewn onto at least one of i) at least a part of the reinforcement zones and ii) the at least one edge of the article at least partially manufactured using a tuck-in device .

21. The method according to any one of claims 15-20, wherein the woven article is woven as a continuous woven article and subsequently cut into pieces .

22. The method according to any one of claims 15-21, wherein the woven article is cut with ultrasonic cutting.

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