Variable-diameter lanyards and systems and methods for making the same

Abstract

Variable-diameter lanyards and systems and methods for manufacturing the same are disclosed. Variable-diameter lanyards can include a variable diameter core with a woven exterior. Tensile members may be included in the variable-diameter core for structural support and added strength.

What is claimed is: 
     
         1 . A variable-diameter lanyard, comprising:
 a variable-diameter core comprising one or more tensile members, wherein a diameter varies smoothly over a length of the variable-diameter core; and   a woven sheath covering the variable-diameter core.   
     
     
         2 . The variable-diameter lanyard of  claim 1 , wherein the one or more tensile members comprise at least one of Kevlar, xylow, nitinol, and steel. 
     
     
         3 . The variable-diameter lanyard of  claim 1 , wherein the variable-diameter core comprises a first end and a second end, wherein a diameter of the variable-diameter lanyard has a minimum diameter at the first and the second ends and a maximum diameter at a point along the length of the variable-diameter core between the first and second ends. 
     
     
         4 . The variable-diameter lanyard of  claim 1 , wherein the variable-diameter core comprises a closed loop. 
     
     
         5 . The variable-diameter lanyard of  claim 3 , wherein the variable-diameter core further comprises:
 a cured resin that encompasses the one or more tensile members; and   a bi-component sheath compression molded from two urethane sheets that encompass the cured resin and the one or more tensile members.   
     
     
         6 . The variable-diameter lanyard of  claim 3 , wherein the variable-diameter core further comprises a bi-component sheath compression molded from two silicone sheets that encompass the one or more tensile members. 
     
     
         7 . The variable-diameter lanyard of  claim 1 , wherein the woven sheath comprises at least one of a synthetic fiber, a metallic fiber, and a natural fiber. 
     
     
         8 . The variable-diameter lanyard of  claim 2 , further comprising a device engagement region. 
     
     
         9 . The variable-diameter lanyard of  claim 8 , wherein the device engagement region comprises an overmold member configured to couple together the first end and the second end of the variable-diameter lanyard. 
     
     
         10 . The variable-diameter lanyard of  claim 9 , further comprising a loop coupled to the overmold member. 
     
     
         11 . The variable-diameter lanyard of  claim 9 , further comprising a fastener coupled to the overmold member. 
     
     
         12 . The variable-diameter lanyard of  claim 1 , wherein the variable-diameter core is extruded around the one or more tensile members. 
     
     
         13 . The variable-diameter lanyard of  claim 1 , wherein the variable-diameter core is formed using an injection molding process. 
     
     
         14 . The variable-diameter lanyard of  claim 4 , wherein the woven sheath comprises a first end and a second end, and wherein the first end and the second end of the woven sheath are coupled together. 
     
     
         15 . The variable-diameter lanyard of  claim 14 , wherein the first and second ends of the woven sheath are coupled together with at least one of a splice, a crimp, a sheath overmold, or an adhesive. 
     
     
         16 . A method for forming a variable-diameter lanyard, comprising:
 providing a material to an extruder, the extruder comprising a die through which the material is extruded;   feeding a tensile member through a hypodermal path extending through a portion of the die;   extruding the material through the die while the tensile member is fed through the hypodermal path, wherein the extruded material surrounds the tensile member to form a variable-diameter core;   dynamically adjusting system factors of the extruder to change an outer diameter of the variable-diameter core; and   weaving a sheath over the variable-diameter core.   
     
     
         17 . The method of  claim 16 , wherein the system factors comprise at least one of:
 a line speed;   heat;   a screw rotation speed;   a melt pressure; and   an air pressure.   
     
     
         18 . The method of  claim 16 , wherein the tensile member comprises at least one of Kevlar, aramid fiber, xylow, nitinol, and steel. 
     
     
         19 . The method of  claim 16 , wherein the outer diameter of the variable-diameter core varies from a minimum at a first end, to a maximum at a point along the variable-diameter core, and back to a minimum at a second end. 
     
     
         20 . The method of  claim 19 , wherein the outer diameter of the variable-diameter core varies smoothly along its length. 
     
     
         21 . The method of  claim 16 , further comprising coupling a first end and a second end of the variable-diameter lanyard together. 
     
     
         22 . A method for forming a variable-diameter lanyard, comprising:
 placing one or more tensile members into a variable-diameter mold;   injecting material into the variable-diameter mold;   removing the material from the variable-diameter mold, wherein the material and the tensile member form a variable-diameter core; and   weaving a sheath around the variable-diameter core.   
     
     
         23 . The method of  claim 22 , further comprising:
 placing the one or more tensile members in at least one tube, wherein an inner diameter of the at least one tube is selected based on dimensions of the one or more tensile members;   placing the at least one tube with the tensile member in a variable-diameter mold, wherein an outer diameter of the at least one tube is selected based on dimensions of the variable-diameter mold; and   progressively extracting the at least one tube from the variable-diameter mold while leaving the tensile member in the variable-diameter mold.   
     
     
         24 . The method of  claim 22 , wherein the mold comprises a substantially straight section in which the at least one tube can be received. 
     
     
         25 . The method of  claim 22 , wherein injecting material into the mold comprises injecting material into a single location of the mold. 
     
     
         26 . The method of  claim 22 , wherein injecting material into the mold comprises injecting material into a plurality of locations of the mold. 
     
     
         27 . The method of  claim 22 , further comprising placing the tensile member under tension after it is placed in the mold. 
     
     
         28 . A method comprising:
 providing a variable-diameter core; and   weaving a sheath around the variable-diameter core.   
     
     
         29 . The method of  claim 28 , wherein providing the variable-diameter core comprises at least one of a compression molding process, a bump extrusion process, and an injection molding process. 
     
     
         30 . The method of  claim 28 , further comprising providing one or more tensile members in the variable-diameter core.