HK1237610A1 - Three dimensional weave fabric for producing a woven item - Google Patents

Description

Three-dimensional woven fabric for producing woven articles

Cross Reference to Related Applications

This application claims priority to U.S. provisional application No. 62/038598, filed on 8/18/2014, which is incorporated herein by reference in its entirety.

Background

The present invention relates generally to one or more woven tubular fabrics having unwoven areas produced by a novel weaving technique. More particularly, the present disclosure relates to three-dimensional woven tubular fabrics for producing woven hats and other articles that provide performance enhancement, aesthetic functionality.

Fabrics are usually made from corresponding raw materials and are constructed by weaving, knitting, plaiting or braiding. For example, felted fabrics are produced by entangling fibres. Fabrics are largely classified by their standard production methods into woven, knitted, felted, laced, non-woven, laminated and molded fabrics.

In a narrow sense, a woven fabric refers to a fabric or fabric part constructed by interweaving vertical warp yarns with horizontal weft yarns at right angles. Woven fabrics are the most widely used fabrics for underwear and outerwear. The knitted fabric is constructed by combining the yarns into loops and combining the loops with each other in front, rear, left, and right directions. Knitted fabrics are produced quickly by knitting and tend to be loose and elastic when worn. The fiber strands are entangled by heat, moisture, pressure or shock (striking) to construct a felt fabric, thereby eliminating the need to use yarns. In lace fabrics, knits and mesh fabrics, individual yarns are interwoven with groups of yarns while sliding in either direction to achieve the desired effect.

Nonwoven fabrics are constructed by applying a binder material, attaching fibers through chemical functional groups on the fiber surface, or attaching a roll or sheet of thermoplastic fibers by heating. The laminated fabric is constructed by laminating foam to one or both woven fabrics to achieve increased flexibility and provide a soft feel. The surface area of the molded fabric is greater than the surface area of the feedstock prior to extrusion. Molded articles (e.g., garments) are soft, or in the form of a pile or panel.

All of these fabrics are very abrasion resistant, match the function of the human body, and are not easily deformable. Additionally, sewing and other fusing techniques are currently used to impart three-dimensional shapes to fabrics. However, the typical sewing and other fusing techniques currently used to impart three-dimensional shapes to fabrics result in the loss of certain functional attributes and other performance or aesthetic properties.

To overcome the above problems, three-dimensional fabrics have been made which comprise a face layer and a back layer woven together via floats. The face layer and the back layer are woven together to create a predetermined pattern or area in which the two layers are not woven together. Thus, the floats comprise yarns attached to a stitched facing layer and a stitched backing layer in an alternating and repeating pattern. In particular, weaving is controlled by a computer program that weaves or does not weave two layers together. These areas that are not woven together effectively create tubes, reed tunnels (channels) or areas where the yarns do not adhere to the face or back layers. Once weaving is complete, the three-dimensional woven fabric material may be heat treated. When heat treatment is used, the process shrinks the floats, causing the tube or unwoven area to be manipulated (manipulated). In particular, the tubes or unwoven areas may be bulkier (puff) or erect (stand up) than if there were no heat treatment. Alternatively, the unwoven area or the reed pipe or tube can be created by unattached yarn segments creating a space under the yarn that forms the tube or reed pipe. Thus, the new weaving technique, if used, in conjunction with the heat treatment process allows for enhanced performance functions, such as stretching. The woven components produced by the weaving process are then assembled into woven hats or other articles, such as garments, footwear, outerwear, and the like.

Disclosure of Invention

The following presents a simplified summary in order to provide a basic understanding of some aspects of the disclosed invention. This summary is not an extensive overview, and it is not intended to identify key/critical elements or to delineate the scope thereof. Its sole purpose is to present some concepts in a simplified form as a prelude to the more detailed description that is presented later.

In the subject matter disclosed and claimed herein, one aspect thereof includes a three-dimensional or napped area woven textile material for producing woven hats and other articles having textural attributes, such as apparel, footwear, outerwear, apparel accessories, and the like. For example, in addition to creating a raised pattern or other texture elements, branding or other brand or trade dress type indicia may be created.

The three-dimensional woven fabric material comprises two layers of material, a face layer and a back layer. Typically, the facing and backing layers are made of synthetic materials or synthetic blends, such as polyester, however, any other suitable material as known in the art may be used. The face and back layers may then be woven together via floats. The face layer and the back layer are woven together to create a predetermined pattern or area where the two layers are not woven together. These areas that are not woven together create tubes, reed ducts, or free unwoven areas. In particular, weaving is controlled by a computer program, which weaves or does not weave two layers together and can be used to create a wide variety of patterns and designs.

In one exemplary embodiment, once weaving is complete, the three-dimensional woven fabric material is heat treated. The heat treatment process shrinks the floats, allowing the handling tube or profile reed pipe. Specifically, the tubes or unwoven areas are more lofty or upright than if there were no heat treatment. The heat treated three-dimensional woven fabric components are then assembled to produce woven hats or other articles. Specifically, the three-dimensional woven fabric component is shaped to form different sections (or portions) of the woven hat. Woven hats are then produced by assembling a plurality of different woven components.

Additionally, the tubes may be filled with fibers or other suitable materials as known in the art to make the lofty area firmer, or to add texture or other similar features. Further, depending on the needs and desires of the user and manufacturing constraints, the pattern and/or design may be woven over the entire area of the hat, or only in limited areas on the hat, such as locations where brand or trademark indicia may be generated. There may be a plurality of identical patterns and/or designs or a mixture of patterns and/or designs. Patterns and/or designs of different sizes and/or shapes may be created by varying the size of the woven tubes.

In still further embodiments, the unwoven area or tube is not subjected to heat treatment and may remain relatively loose, in the case of a repeating pattern, producing a woven area that is about 1: relative ratio of 1. Other ratios of woven to unwoven areas may also be produced when there is a substantial separation area from the next unwoven area, such that the woven to unwoven area may be between about 1: 2 to about 1: 10, in the range of 10. This ratio is determined by measuring the length and/or width of the woven zone: the length and/or width of the unwoven area.

To the accomplishment of the foregoing and related ends, certain illustrative aspects of the disclosed innovation are described herein in connection with the following description and the annexed drawings. These aspects are indicative, however, of but a few of the various ways in which the principles disclosed herein can be employed and is intended to include all such aspects and their equivalents. Other advantages and novel features will become apparent from the following detailed description when considered in conjunction with the drawings.

Drawings

FIG. 1A illustrates a side view of a three-dimensional woven fabric material prior to heat treatment in accordance with the disclosed structure.

FIG. 1B illustrates a side view of a three-dimensional woven fabric material after heat treatment according to the disclosed structure.

Figure 2 illustrates a perspective view of a face layer and a back layer of a three-dimensional woven fabric material according to the disclosed structure.

FIG. 3 illustrates a front view of a specifically shaped three-dimensional woven fabric component to be assembled into a woven hat in accordance with the disclosed structure.

FIG. 4 illustrates a front view of a specifically shaped three-dimensional woven fabric component to be assembled into a woven hat in accordance with the disclosed structure.

FIG. 5 illustrates a front view of a specifically shaped three-dimensional woven fabric component to be assembled into a woven hat in accordance with the disclosed structure.

FIG. 6 illustrates a front view of a specifically shaped three-dimensional woven fabric component to be assembled into a woven hat in accordance with the disclosed structure.

FIG. 7 illustrates a front view of a specifically shaped three-dimensional woven fabric component to be assembled into a woven hat in accordance with the disclosed structure.

FIG. 8 illustrates a front view of a specifically shaped three-dimensional woven fabric component to be assembled into a woven hat in accordance with the disclosed structure.

FIG. 9 illustrates a front view of a specifically shaped three-dimensional woven fabric component to be assembled into a woven hat in accordance with the disclosed structure.

FIG. 10 illustrates a front view of a specifically shaped three-dimensional woven fabric component to be assembled into a woven hat according to the disclosed structure.

11A-D illustrate perspective views of a three-dimensional woven fabric material in application as a plurality of woven hats in accordance with the disclosed structure.

Detailed Description

The present invention is now described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding thereof. It may be evident, however, that the invention may be practiced without these specific details. In other instances, well-known structures and devices are shown in block diagram form in order to facilitate a description thereof.

Currently, sewing and other fusion techniques are used to impart three-dimensional shapes to fabrics. However, the typical sewing and other fusing techniques currently used to impart three-dimensional shapes to fabrics result in loss of stretch and other desired functional and other performance characteristics. To overcome the above problems, three-dimensional woven fabric materials for producing woven hats and other articles, such as garments, outerwear, footwear, accessories, and the like, are disclosed. The three-dimensional woven fabric material comprises two layers of material, a face layer and a back layer. The face layer and the back layer are then woven together via floats to create a predetermined pattern or area in which the two layers are not woven together.

These areas that are not woven together create a tube. In particular, weaving is controlled by a computer program that weaves or does not weave two layers together. Once weaving is complete, the three-dimensional woven fabric material may be heat treated or subjected to other post-weaving treatments or not at all. If a heat treatment process is used, the heat shrinks the floats, causing the handling tubes, profile reed ducts, or unwoven areas. Specifically, the tube is more fluffy or upright than if not heat treated. Additionally, the tubes may be filled with fibers or other suitable materials to make the lofty area more solid. The heat treated three-dimensional woven fabric component is then assembled into a woven hat or other article.

For example, in constructing hats or other apparel accessories such as footwear, purses, and as seen in the drawings, the individual components, side, rear, front, top, bottom, etc., may be individually woven to create a unique design or the same design or one or more components on each component. For example, several individual components may have a repeating pattern, while another component may have a brand-distinguishing element, such as a trademark. Once all of the components are woven, the individual components may be sewn together to form the finished product. For example, in the case of forming a hat, there may be six individual components which are then assembled to form a particular piece.

Referring initially to the drawings, FIGS. 1A-B and 2 illustrate a three-dimensional woven fabric material 100 for producing woven hats and other articles. The use of three-dimensional woven fabric to produce woven hats is only one possible example, and the same fabric material may be used for any suitable application. Thus, although the term "fabric" is used throughout this disclosure for exemplary purposes, the term "fabric" may be any single item or material, or group of items or materials.

The three-dimensional woven fabric material 100 comprises two layers of material, a face (or surface) layer 102 or a backsheet 104 (as shown in figure 2). Typically, the face layer 102 and the backing layer 104 are made of a synthetic material or synthetic blended yarn, such as polyester, however, any other suitable material as known in the art may be used without affecting the overall concept of the present invention. The face layer 102 and the backing layer 104 can be any suitable shape and size depending on the needs and desires of the user and manufacturing constraints.

The face layer 102 and the back layer 104 are then woven together via yarns 106. Yarn 106 is preferably a float-knit lycra yarn, however, yarn 106 may be any other suitable material as known in the art. For example, the yarns 106 used may be monofilament yarns, multifilament yarns, spun yarns, etc., as desired, and these yarns 106 may be made of artificial, natural or synthetic fibers, depending on the needs and desires of the user and/or manufacturing constraints. Yarn 106 may also be an elastic or inelastic yarn, or various combinations thereof. The type of yarns 106 and number of yarns 106 that weave the face layer 102 and the backing layer together throughout the body of the fabric material 100 may vary widely and will be primarily controlled by the desired end use of the fabric material 100. Typically, the yarn 106 has a denier of from 30 to 300 and preferably between 70 and 300 denier.

The face layer 102 and the back layer 104 are woven together to create a predetermined pattern or area in which the two layers 102 and 104 are not woven together. These areas that are not woven together create tubes (reed ducts or gaps or hollow portions of double layer fabric) 108. Specifically, the weaving is controlled by a computer program that weaves or does not weave the two layers 102 and 104 together. Typically, three-dimensional textile material 100 is produced on a custom-made or specially constructed weaving machine that incorporates a computer program to control the activity of yarn 106.

Accordingly, the facing layer 102 includes sequential unstitched surface portions and sequential stitched surface portions formed in an alternating and repeating pattern. For example, a standard weave would continue row by row. Then, when a tube or gap 108 is to be formed, the floats 106 are pushed into the two layers 102 and 104 (similar to a sewing machine), and then weaving or sewing is stopped and restarted when sufficient space has been created for forming the gap or tube 108. The ratio of the spacing between the woven and unwoven areas may be in the range from almost 0-1: 10 or even higher. Specifically, the warp yarns (or warp yarns of the weave) are split, creating the gaps or tubes 108. The process is then repeated row by row until the weaving is completed.

In one exemplary embodiment, once weaving is complete (as shown in fig. 1A), the three-dimensional woven fabric material 100 is heat treated. The three-dimensional woven fabric material 100 may be heat treated via any suitable heat treatment process as is known in the art. The heat treatment process shrinks the floats 106, allowing the tube or gap 108 to be manipulated. Specifically, the tube or gap 108 is more lofty or upright (as shown in FIG. 1B) than if there were no heat treatment. The use of synthetic materials or synthetic blended yarns for layers 102 and 104 allows for thermal processing to shrink the synthetic materials to create lofty or raised areas that are readily distinguishable from surrounding areas. The greater the surface area present on the material, the more loft can be created by heat treatment, and of course, given their individual fashion preferences or designs of the end user, they prefer that the surface area be covered with a large number of raised areas. Typically, the lofty design extends into both plies of the three-dimensional woven fabric material 100, creating a three-dimensional design. However, the lofty design may be manipulated so as to be more enlarged on one side or layer than the other. Additionally, the tubes or gaps 108 may be filled with fibers or other suitable materials as known in the art to make the lofty area firmer, or to add texture or other similar features.

Accordingly, three-dimensional woven fabric material 100 may be of any suitable size, shape, and pattern as known in the art without affecting the overall concept of the present invention. Those of ordinary skill in the art will appreciate that the sizes and/or shapes of the face layer 102 and the back layer 104 shown in fig. 1A and 1B are for illustrative purposes only, and that many other sizes and/or shapes of the layers 102 and 104 are within the scope of the present disclosure. Although the dimensions (i.e., length, width, and height) of layers 102 and 104 are important design parameters for good performance, layers 102 and 104 may be any size and/or shape that ensures optimal stretch function and other performance characteristics.

Fig. 3-10 illustrate three-dimensional woven fabric materials formed into different segments (or portions) of a hat. Specifically, fig. 3-10 disclose a plurality of heat treated three-dimensional woven fabric components 300, 400, 500, 600, 700, 800, 900, 1000 having specific shapes and sizes depending on the needs and desires of the user and/or manufacturing constraints. These three-dimensional woven fabric components are shaped to form different sections (or portions) of the woven hat. Woven hats are then produced by assembling a plurality of different woven components 300, 400, 500, 600, 700, 800, 900, 1000 together (as shown in fig. 11). Specifically, different portions of the woven hat are separated and then four to six different woven components are created by heat treating the woven fabric material. Once the woven components are heat treated, the components are assembled together into a finished hat (see fig. 11). Alternatively, no heat may be applied to the part, which will still create texture differences in the product itself when compared to the surrounding area of the product.

The woven components may be assembled into any suitable hat or cap as known in the art and thus the size and shape of the tubes or profile reed ducts or gaps in the components is adjusted depending on the size and shape of the hat to be produced and the particular design being produced. Those of ordinary skill in the art will appreciate that the size and/or shape of the woven component 300, 400, 500, 600, 700, 800, 900, 1000 heat treated as shown in fig. 3-10 is for illustrative purposes only, and that other sizes and/or shapes of woven components are well within the scope of the present disclosure. While the dimensions (i.e., length, width, and height) of the woven component are important design parameters for good performance, the profile reed ducts, gaps, tubes of the woven component can be any size and/or shape that ensures optimal function such as stretch and other performance characteristics.

11A-D illustrate a plurality of woven hats produced from three-dimensional woven fabric 100 components, wherein at least one of the components has one or more unwoven areas that form tubes, reed tunnels, or gaps in the weave. Specifically, a plurality of woven components (300, 400, 500, 600, 700, 800, 900, 1000) are produced (as shown in fig. 3-10), and then the plurality of woven components (300, 400, 500, 600, 700, 800, 900, 1000) are assembled into woven hats (1100, 1102, 1104, 1106), which are 100% woven, possibly in addition to the bill or brim (or visor) of the woven hat, which will include additional stiffening components, such as cardboard, paperboard, etc., to provide the necessary strength to the bill or brim of the hat.

The heat treated three-dimensional woven fabric component may be fabricated or produced into different textures or designs by varying the heat treatment, yarn color, weave design. Specifically, four unique designs or textures (i.e., stone (stone), snake (snake), leopard (leopard), and geometric shapes) produced by woven hats are shown in fig. 11A-D, and in this particular example, form a "baseball style" style hat or cap. All unique designs show vivid colors and details and differ from ordinary fabric feel by distinct wrinkles (puff) and ridges created by forming reed pipes, tubes or gaps in the weaving of the fabric and then subjecting the woven components to possible post-weaving treatments such as heat treatment. Specifically, fig. 11A discloses a woven hat 1100 with a leopard print pattern and an elongated bill. Fig. 11B discloses a woven hat 1102 having a serpentine pattern and an elongated bill. Fig. 11C discloses a woven hat with a stone color/pattern and a circular bill or brim. Fig. 11D discloses a woven hat 1106 having a geometric pattern and an elongated bill.

Further, depending on the needs and desires of the user and manufacturing constraints, the pattern and/or design may be woven over the entire area of the hat or only in a limited area on the hat. Any pattern and/or design may be woven, and the pattern and/or design may have any shape or size. There may be a plurality of identical patterns and/or designs, or a mixture of patterns and/or designs. Large patterns and/or designs may be used, or small patterns and/or designs may be used, or a combination of both large and small patterns and/or designs. Patterns and/or designs of different sizes and/or shapes are created by varying the size of the woven tubes or gaps. Any size and/or shape of hat or other article may be created with a pattern and/or design. Further, patterns and/or designs may be used in woven labels, such as those found on the interior of clothing or hats, to aid in branding.

What has been described above includes examples of the claimed subject matter. It is, of course, not possible to describe every conceivable combination of components or methodologies for purposes of describing the claimed subject matter, but one of ordinary skill in the art may recognize that many further combinations and permutations of the claimed subject matter are possible. Accordingly, the claimed subject matter is intended to embrace all such alterations, modifications and variations that fall within the spirit and scope of the appended claims. Furthermore, to the extent that the term "includes" is used in either the detailed description or the claims, such term is intended to be inclusive in a manner similar to the term "comprising" as "comprising" is interpreted when employed as a transitional word in a claim.

Claims (20)

1. A three-dimensional woven fabric material hat comprising:

a plurality of three-dimensional woven textile components woven into a plurality of predetermined shapes, wherein each of the plurality of three-dimensional woven textile components comprises:

a surface layer; and

a back layer;

wherein the face layer is woven to the back layer via a plurality of floats to create a predetermined pattern; and

wherein the predetermined pattern comprises tubes that are areas where the face layer and the back layer are not woven together; and

wherein the plurality of three-dimensional woven fabric components are assembled to form a woven hat.

2. The three dimensional weave fabric material hat of claim 1, wherein the weaving is controlled by a computer program that weaves or does not weave the face layer and the back layer together.

3. The three-dimensional woven fabric material hat of claim 2, wherein the tube is subjected to a heat shrinking process that shrinks the floats.

4. The three dimensional weave fabric material hat of claim 1, wherein the lofty tube may be manipulated such that the loft is expanded more over the face layer.

5. The three dimensional weave fabric material hat of claim 1, wherein the lofty tube can be manipulated such that the loft is expanded more on the backing layer.

6. The three-dimensional weave fabric material hat of claim 1, wherein the predetermined pattern is woven over an entire area of the woven hat.

7. The three-dimensional weave fabric material hat of claim 1, wherein the predetermined pattern is woven over a limited area of the woven hat.

8. The three dimensional weave fabric material hat of claim 1, wherein the tubes are filled with fibers to add texture.

9. A three-dimensional woven fabric material for producing woven hats, comprising:

a surface layer; and

a back layer;

wherein the face layer is woven to the back layer via a plurality of yarns to create a predetermined pattern; and

wherein the predetermined pattern comprises tubes that are areas where the face layer and the back layer are not woven together; and

wherein the tube is manipulated such that the tube is fluffy.

10. The three-dimensional woven fabric material for producing woven hats of claim 9, wherein the three-dimensional woven fabric material is woven into a plurality of predetermined shapes.

11. The three-dimensional woven fabric material for producing woven hats of claim 10, wherein the plurality of predetermined shaped materials are assembled to form a woven hat.

12. The three-dimensional weave fabric material for producing woven hats of claim 11, wherein the weaving is controlled by a computer program that weaves or does not weave the face layer and the back layer together.

13. The three-dimensional woven fabric material for producing woven hats of claim 12, wherein the tubes are filled with fibers to add texture.

14. The three-dimensional woven fabric material for producing woven hats of claim 9, wherein the predetermined pattern is woven over an entire area of the woven hat.

15. The three-dimensional weave fabric material for producing woven hats of claim 9, wherein the predetermined pattern is woven over a limited area of the woven hat.

16. The three-dimensional weave fabric material for producing woven hats of claim 9, further comprising a blend of more than one predetermined pattern across an area of the woven hat.

17. A three-dimensional woven fabric material for clothing comprising

A surface layer; and

a back layer;

wherein the face layer is woven to the back layer via a plurality of floats to create a predetermined pattern; and

wherein the predetermined pattern comprises tubes that are areas where the face layer and the back layer are not woven together; and

wherein the tube is manipulated via a heat shrinking process to shrink the floats so that the tube is lofty;

wherein the tube is filled with fibers to increase texture; and

wherein the weaving is controlled by a computer program which weaves or does not weave the face layer and the back layer together.

18. The three-dimensional woven fabric of claim 17, wherein the garment is a woven hat.

19. The three-dimensional woven fabric of claim 17, wherein the three-dimensional woven fabric can be applied in a woven label on the interior of a garment.

20. The three-dimensional woven fabric of claim 18, wherein the pattern of different sizes and shapes is created by varying the size of the tubes woven.