阅读说明：本技术 多层和多功能编织织物及其制造方法 (Multi-layer and multi-functional woven fabric and method of making same ) 是由 S·比格尔 Y·王 D·阿加瓦尔 于 2018-09-21 设计创作，主要内容包括：多层织物至少包括第一编织织物层和附接至第一编织织物层的第二编织织物层。第一编织织物层为多层织物提供第一功能性,第二编织织物层为多层织物提供第二功能性,并且第一功能性不同于第二功能性。用于形成多层织物的方法包括在织机上编织第一编织织物层,第一编织织物层具有第一功能性；在织机上编织至少第二编织织物层,第二编织织物层具有不同于第一功能性的第二功能性；和在第一编织织物层和第二编织织物层处于织机上时,将第二编织织物层附接至第一编织织物层。多层织物可以包括多个织物层,如2至8个织物层。(The multi-layer fabric includes at least a first woven fabric layer and a second woven fabric layer attached to the first woven fabric layer. The first woven fabric layer provides a first functionality to the multi-layer fabric, the second woven fabric layer provides a second functionality to the multi-layer fabric, and the first functionality is different from the second functionality. A method for forming a multi-layer fabric includes weaving a first woven fabric layer on a loom, the first woven fabric layer having a first functionality; weaving at least a second woven fabric layer on the loom, the second woven fabric layer having a second functionality different from the first functionality; and attaching the second woven fabric layer to the first woven fabric layer while the first and second woven fabric layers are on the loom. The multilayer fabric may comprise a plurality of fabric layers, such as 2 to 8 fabric layers.)

1. A multilayer fabric comprising at least a first woven fabric layer and a second woven fabric layer attached to the first woven fabric layer, wherein:

the first knitted fabric layer provides a first functionality to the multi-layer fabric;

the second knitted fabric layer provides a second functionality to the multi-layer fabric; and is

The first functionality is different from the second functionality.

2. The multilayer fabric of claim 1, wherein the first functionality and the second functionality are selected from one or more of the following: warming, cooling, season-long, flame retardancy, antibacterial, odor control, retroreflectivity, ultraviolet protection, abrasion resistance, energy tolerance, water repellency, wind resistance, thermal conductivity, electrical conductivity, stretch, non-stretch, softness, hand feel, nub, fabric smoothness, yarn size, printability, dyeability, color change, style change, responsiveness, energy boost, skin moisturization, Infrared (IR) transmission, infrared reflection, infrared absorption, ventilation, controlled shrinkage, sensory properties, aesthetic appearance, and aesthetic feel.

3. The multilayer fabric of claim 1 or 2, wherein the first knitted fabric layer comprises first yarns knitted into a first fabric construction, and the first functionality is provided by one or more of the first yarns and first fabric construction.

4. The multilayer fabric of claim 3, wherein the first yarns are woven in a warp direction and a weft direction into the first fabric construction, and the first functionality is provided by the first yarns woven in the warp direction, the first yarns woven in the weft direction, or the first yarns woven in the warp direction and the weft direction.

5. The multilayer fabric of any one of claims 1 to 4, wherein the second knitted fabric layer comprises second yarns knitted into a second fabric construction, and the second functionality is provided by one or more of the second yarns and the second fabric construction.

6. The multilayer fabric of claim 5, wherein the second yarns are woven in a warp direction and a weft direction into the second fabric construction, and the second functionality is provided by the second yarns woven in the warp direction, the second yarns woven in the weft direction, or the second yarns woven in the warp direction and the weft direction.

7. The multilayer fabric of claim 5 or 6, wherein the first fabric construction comprises a first weave type and the second fabric construction comprises a second weave type, and the first weave type and the second weave type are independently selected from plain weave, twill weave, satin weave, pile weave, mini-jacquard weave, knit look weave, anti-rip weave, derivatives thereof, and combinations thereof.

8. The multilayer fabric of any one of claims 1 to 7, wherein the second woven fabric layer is attached to the first woven fabric layer in a warp direction, a weft direction, or in both the warp and weft directions.

9. The multilayer fabric of any one of claims 1 to 8, further comprising an air pocket between the second woven fabric layer and the first woven fabric layer, the air pocket resulting from an attachment between the second woven fabric layer and the first woven fabric layer.

10. The multilayer fabric of claim 8 or 9, wherein the attaching is in an adjustable pattern such that the air pockets are formed in the multilayer fabric in an adjustable pattern, having an adjustable size.

11. A method of forming a multi-layer fabric comprising:

weaving a first fabric layer on a loom, the first fabric layer having a first functionality;

weaving at least a second fabric layer on the loom, the second fabric layer having a second functionality different from the first functionality; and

attaching the second fabric layer to the first fabric layer while the first fabric layer and the second fabric layer are on the loom.

12. The method of claim 11, wherein the loom comprises a single warp beam or a plurality of warp beams.

13. The method of claim 11 or 12, further comprising:

weaving at least a third fabric layer on the loom, the third fabric layer having a third functionality, the third functionality being different from one or both of the first functionality and the second functionality; and

attaching the third fabric layer to one or both of the first fabric layer and the second fabric layer.

14. The method of any one of claims 11 to 13, wherein the multilayer fabric comprises 2 to 8 woven fabric layers.

15. A garment formed from the multilayer fabric of any one of claims 1 to 14, wherein the garment comprises a jacket, pants, jeans, hat, shirt, gown, coverall, or sportswear.

Technical Field

The present disclosure relates to multilayer woven fabrics, and in particular to multilayer and multifunctional woven fabrics, wherein each layer provides different functionality to the woven fabric.

Background

Various forms of double layer fabrics are available on the garment market. In one form, two or more separately woven or knitted fabrics are combined together using laminate bonding or by sewing/sewing the fabrics together. Another form is a double layer pile fabric (fly fabric). Although garments made from these types of constructions may provide certain functions, such as warming (warming), wind protection, etc., they also have various drawbacks. For example, fabrics are bulky (bulk), the process for making the fabric is costly and inefficient, the fabric lacks breathability (particularly in laminate constructions comprising films such as polytetrafluoroethylene), and the aesthetics of the fabric may be compromised.

Aspects of the present disclosure address these and other shortcomings.

Disclosure of Invention

Aspects of the present disclosure relate to a multilayer fabric including at least a first woven fabric layer and a second woven fabric layer attached to the first woven fabric layer. The first woven fabric layer provides a first functionality to the multi-layer fabric, the second woven fabric layer provides a second functionality to the multi-layer fabric, and the first functionality is different from the second functionality. The multilayer fabric may comprise a plurality of fabric layers, such as 2 to 8 fabric layers.

Aspects of the present disclosure also relate to methods for forming a multilayer fabric, comprising: weaving a first woven fabric layer on a loom, the first woven fabric layer having a first functionality; weaving at least a second woven fabric layer on the loom, the second woven fabric layer having a second functionality different from the first functionality; and attaching the second woven fabric layer to the first woven fabric layer while the first and second woven fabric layers are on the loom. The multilayer fabric may comprise a plurality of fabric layers, such as 2 to 8 fabric layers.

Drawings

In the drawings, which are not necessarily drawn to scale, like numerals may describe similar components in different views. Like numerals having different letter suffixes may represent different instances of similar components. The drawings illustrate generally, by way of example, but not by way of limitation, various embodiments discussed in the present document.

Fig. 1 is an example of a multilayer fabric according to aspects of the present disclosure.

Fig. 2A-2C are annotated photographs of a multilayer fabric according to aspects of the present disclosure.

Fig. 3 is a flow chart illustrating a method for manufacturing a multi-layer fabric according to aspects of the present disclosure.

Fig. 4 is an example of a multilayer fabric according to aspects of the present disclosure.

Fig. 5A-C are examples of double-layer multilayer fabrics according to other aspects of the present disclosure.

Fig. 6A and 6B are examples of 3-layer and 4-layer multilayer fabrics according to aspects of the present disclosure.

Fig. 7A and 7B are examples of prior art pile fabrics (fig. 7A) and multi-layer (double layer) denim fabrics according to aspects of the present disclosure.

Detailed Description

The present disclosure may be understood more readily by reference to the following detailed description of the disclosure and the examples included therein. In various aspects, the present disclosure relates to a multilayer fabric comprising at least a first woven fabric layer and a second woven fabric layer attached to the first woven fabric layer. The first woven fabric layer provides a first functionality to the multi-layer fabric, the second woven fabric layer provides a second functionality to the multi-layer fabric, and the first functionality is different from the second functionality.

Before the present compounds, compositions, articles, systems, devices, and/or methods are disclosed and described, it is to be understood that it is not limited to specific synthetic methods, unless otherwise specified, or to specific reagents, unless otherwise specified, as such can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting.

The present disclosure encompasses various combinations of elements of the present disclosure, for example, combinations of elements in dependent claims dependent on the same independent claim.

Further, it should be understood that, unless explicitly stated otherwise, it is in no way intended that any method described herein be construed as requiring that its steps be performed in a specific order. Thus, where a method claim does not actually define an order to be followed by its steps or where steps not otherwise specifically stated in the claims or specification are to be limited to a specific order, it is in no way intended that an order be inferred, in any respect. This applies to any possible non-explicit basis for interpretation, including: logical issues regarding the arrangement of steps or operational flow; simple meaning from grammatical organization or punctuation; and the number or type of embodiments described in the specification.

All publications mentioned herein are incorporated herein by reference to disclose and describe the methods and/or materials in connection with which the publications are cited.

Definition of

It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting. As used in the specification and claims, the term "comprising" may include embodiments "consisting of … …" and "consisting essentially of … …". Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. In this specification and the claims which follow, reference will be made to a number of terms which are defined herein.

As used in the specification and the appended claims, the singular forms "a", "an", and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to "a fiber" includes mixtures of two or more fibers.

As used herein, the term "combination" includes blends, mixtures, alloys, reaction products, and the like.

Ranges may be expressed herein as from one value (a first value) to another value (a second value). When such a range is expressed, the range in some aspects includes one or both of the first value and the second value. Similarly, when values are expressed as approximations, by use of the antecedent "about," it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint. It will also be understood that a plurality of values are disclosed herein, and that each value is also disclosed herein as "about" that particular value in addition to the value itself. For example, if the value "10" is disclosed, then "about 10" is also disclosed. It is also understood that units between two particular units are also disclosed. For example, if 10 and 15 are disclosed, 11, 12, 13 and 14 are also disclosed.

As used herein, the terms "about" and "at or about" mean that the amount or value recited may be a specified value, approximate the specified value, or about the same as the specified value. It is generally understood that, as used herein, it is the nominal value shown ± 10% difference unless otherwise indicated or inferred. The term is intended to convey that similar values promote equivalent results or effects as defined in the claims. That is, it is to be understood that the quantities, dimensions, formulations, parameters, and other quantities and characteristics are not and need not be exact, but may be approximate and/or larger or smaller, as desired, reflecting tolerances, conversion factors, rounding off, measurement error and the like, and other factors known to those of skill in the art. In general, an amount, size, formulation, parameter or other quantity or characteristic is "approximate" or "approximate" whether or not explicitly indicated. It is to be understood that where "about" is used before a quantitative value, unless otherwise specifically stated, the parameter also includes the specific quantitative value itself.

As used herein, the term "optional" or "optionally" means that the subsequently described event or circumstance may or may not occur, and that the description includes instances where said event or circumstance occurs and instances where it does not. For example, the phrase "optional additional woven fabric layer" means that the additional woven fabric layer(s) may or may not be included, and the present disclosure includes multilayer fabrics including the additional woven fabric layer(s) and multilayer fabrics not including the additional woven fabric layer(s).

Unless stated to the contrary herein, all test standards are the most current standards in force at the time of filing the present application.

Each of the materials disclosed herein is commercially available and/or methods for their production are known to those skilled in the art.

It is understood that the compositions disclosed herein have certain functions. Certain structural requirements for performing the disclosed functions are disclosed herein, and it should be understood that there are a variety of structures that can perform the same functions associated with the disclosed structures, and that these structures will generally achieve the same results.

Multi-layer fabric

Referring to fig. 1, aspects of the present disclosure relate to a multilayer fabric 100 including at least a first woven fabric layer 120 and a second woven fabric layer 140 attached 160 to the first woven fabric layer 120. The first woven fabric layer 120 provides a first functionality (e.g., a property, characteristic, property, or attribute) to the multi-layer fabric 100, and the second woven fabric layer 140 provides a second functionality to the multi-layer fabric 100. The first functionality is different from the second functionality.

The first functionality and the second functionality may be any desired property, feature, characteristic, or attribute of the fabric. In some aspects, the first functionality and the second functionality are selected from one or more of the following: warming, cooling, season-wide, flame retardancy, antibacterial, odor control, retroreflectivity, ultraviolet protection, rub resistance, abrasion resistance, energy tolerance, water repellency, water resistance, wind resistance, moisture absorption (perspiration), thermal conductivity, electrical conductivity, stretch, non-stretch, softness, hand feel, nubs, fabric smoothness, yarn size, printability, dyeability, color change, pattern change, responsiveness (e.g., the yarn may be responsive such that properties including, but not limited to, yarn color, yarn size, yarn twist may change as a function of humidity, temperature, and pH), energy boost, skin moisturizer, Infrared (IR) transmission, IR reflection, IR absorption, ventilation, controlled shrinkage, sensory properties, and aesthetic appearance or feel (e.g., moisture, and pH change), energy boost, moisture retention, moisture absorption, air permeability, and/or moisture absorption Rough, smooth, silky, tacky, patterned (patterns), wet/damp, dry hand).

First woven fabric layer 120 and second woven fabric layer 140 may each include more than one functionality (which may overlap) and provide these functionalities to multilayer fabric 100. For example, if the first woven fabric layer 120 provides flame retardant, water resistant, and warming functionality and the second woven fabric layer 140 provides warming and moisture absorbent functionality, the total (collective) functionality provided by the first woven fabric layer 120 to the multilayer fabric 100 is different than the total functionality provided by the second woven fabric layer 140 to the multilayer fabric 100.

The first knitted fabric layer 120 includes a first yarn knitted into a first fabric construction. The first fabric construction includes a first weave type, which may include plain weave, twill weave, satin weave, pile weave, mini-jacquard weave, knit-look (knit-look) weave (i.e., a weave that simulates the look of a knit fabric), rip-stop weave (rip-stop), derivatives thereof, and combinations thereof. As used herein, a "derivative type" of weave is a variation of the traditional weave type of weave described above. For example, a conventional plain weave is a 1x1 weave. The 2x2 plain weave or the square flat weave may be considered a derivative of the plain weave. Similarly, a conventional twill weave repeats over three or more warp (ends) and weft (picks) of the fabric and creates diagonal lines in the face of the fabric. The twill-derived weave may be any twill weave that deviates from this pattern (e.g., a 4x1 twill, a 5x1 twill, etc.).

The first yarns are woven in a warp direction and a weft direction into a first fabric construction. The first yarns woven in the warp direction and the first yarns woven in the weft direction may comprise the same/identical yarn types (e.g., the same yarn fiber type, the same fiber form, the same yarn size, and the same color) or may have different yarn types (e.g., the yarns in the warp and weft directions may have different fibers, different forms, different yarn sizes, and/or different colors).

In some aspects, the first functionality is provided by the first yarn, such as by the fibers selected for the first yarn, the form of the fibers (e.g., spun or filament yarns), the yarn size, and/or the yarn color. In other aspects, the first functionality is provided by the first textile construction, such as by selection of a first weave type. In a further aspect, the first functionality is provided by both the first yarn and the first textile construction. In some aspects, the first functionality is provided by a first yarn woven in a warp direction, by a first yarn woven in a weft direction, or by a first yarn woven in both the warp and weft directions.

Second knitted fabric layer 140 includes a second yarn knitted into a second fabric construction. The second fabric construction includes a second weave type that may include plain weave, twill weave, satin weave, pile weave, mini-jacquard weave, knit look weave, rip stop weave, derivatives thereof, and combinations thereof.

The second yarns are woven in the warp and weft directions into a second fabric construction. The second yarns woven in the warp direction and the second yarns woven in the weft direction may comprise the same/identical yarn types (e.g., the same yarn fiber type, the same fiber form, the same yarn size, and the same color) or may have different yarn types (e.g., the yarns in the warp and weft directions may have different fibers, different forms, different yarn sizes, and/or different colors).

In some aspects, the second functionality is provided by the second yarn, such as by the fibers selected for the second yarn, the form of the fibers (e.g., spun or filament yarns), the yarn size, and/or the yarn color. In other aspects, the second functionality is provided by a second textile construction, such as by selection of a second weave type. In a further aspect, the second functionality is provided by both the second yarn and the second fabric construction. In some aspects, the second functionality is provided by a second yarn that weaves in the warp direction, by a second yarn that weaves in the weft direction, or by a second yarn that weaves in the warp and weft directions.

The first yarn and the second yarn may be independently selected from spun yarns, filament yarns, fancy yarns, bicomponent yarns, core-sheath hybrid yarns, or combinations thereof. The core-sheath hybrid yarn includes a core of one or more filament yarns wrapped with a spun yarn sheath.

The spun yarn may comprise staple fibers including, but not limited to, cotton, flax, jute, hemp, ramie, bamboo, pineapple, banana, wool, beans, milk, cashmere, silk, kapok, polyester, nylon (including, but not limited to, nylon 6 and nylon 66), polypropylene, acrylic (acrylic), rayon (rayon), cellulose, acetate, viscose, modal, lyocell, para-aramid, meta-aramid, polytetrafluoroethylene, FR cotton, FR polyester, FR nylon, polylactic acid (PLA), poly (trimethylene terephthalate) (PTT), Polybenzimidazole (PBI), conductive fibers, optical fibers, copolymers thereof, blends thereof, and combinations thereof.

The filament yarn may comprise fibers including, but not limited to, polyester, nylon (including, but not limited to, nylon 6 and nylon 66), polyethylene, polypropylene, acrylic, cellulose acetate, viscose, modal, lyocell, meta-aramid, para-aramid, polytetrafluoroethylene, FR polyester, FR nylon, melamine, modacrylic, elastomeric fibers (including, but not limited to, spandex), polylactic acid (PLA), poly (trimethylene terephthalate) (PTT), Polybenzimidazole (PBI), conductive fibers, optical fibers, bicomponent filaments comprising two of these fibers, multicomponent filaments comprising three or more of these fibers, copolymers thereof, blends thereof, and combinations thereof. One exemplary bicomponent fiber includes polyester and nylon, such as AeroReact fiber available from Nike. Another exemplary bicomponent fiber includes cellulose and acetate, such as VENTCOLOL available from Mitsubishi Chemical^TMA fiber. Fabrics formed from bicomponent fibersIn combination with proper fabric construction, good moisture management, breathability and thermal regulation properties are provided because when the fiber becomes wet (e.g. due to perspiration), it expands, allowing more moisture and heat from the body to escape. In addition, the fibers are quick drying and therefore shrink quickly, providing good warmth to the wearer.

In a particular aspect, the first yarn and the second yarn comprise spun yarns comprising cotton staple fibers, and both the first weave type and the second weave type are twill weaves. Twill woven fabrics formed from cotton spun yarns are commonly referred to as denim/coverall fabrics. Thus, certain aspects of the present disclosure include a multi-layer denim/coverall fabric having a denim/coverall first woven fabric layer 120 and a denim/coverall second woven fabric layer 140, but one or both of the denim/coverall fabric layers includes other fibers such that the two fabric layers have different functionalities.

As noted, second woven fabric layer 140 is attached 160 to first woven fabric layer 120. Second woven fabric layer 140 may be attached 160 to first woven fabric layer 120 in any suitable manner. In some aspects, the second woven fabric layer 140 is attached 160 to the first woven fabric layer 120 in the warp direction, the weft direction, or in both the warp and weft directions. The attachment 160 of the second woven fabric layer 140 to the first woven fabric layer 120 creates an air pocket between the first woven fabric layer 120 and the second woven fabric layer 140. The size and configuration of the airbag can be adjusted based on the attachment pattern, as shown in fig. 2A-2C. In fig. 2A, the second woven fabric layer 140 is tightly attached 160 to the first woven fabric layer 120 in both the warp and weft directions, creating a substantially square shaped air pocket (see black lines, provided for ease of reference). In fig. 2B, the second woven fabric layer 140 is less tightly attached 160 to the first woven fabric layer 120 in both the warp and weft directions, creating a larger air pocket of generally square shape (see black lines, provided for ease of reference). In fig. 2C, second woven fabric layer 140 is broadly attached 160 to first woven fabric layer 120 in only one direction (e.g., the warp direction) to create a wide longitudinal air pocket (see black lines, provided for ease of reference). In this way, the attachment can be made in a pattern: so that air pockets are formed in the multi-layer fabric 100 in a pattern. Although the examples describe square air pockets and longitudinal air pockets, it will be appreciated that other air pocket configurations (e.g., rectangular, triangular, etc.) may be formed in the multi-layer fabric 100 by utilizing different attachment patterns. In this manner, air pockets may be formed in the multi-layer fabric 100 in an adjustable pattern, with adjustable dimensions.

In some aspects, the air pockets provide thermal insulation for the multi-layer fabric 100. In other aspects, the air pockets provide other functionality to the multi-layer fabric 100. By way of example only, The air pocket may be filled with one or more materials, including but not limited to insulation (e.g., lower insulation and composite insulation, including but not limited to ThermoBall from The North Face)^TMInsulation), fibrous fillers, aerogel fibers, and electronics (sensors, actuators, and wires).

First woven fabric layer 120 and second woven fabric layer 140 of multi-layer fabric 100 may be woven simultaneously on the same loom. Although multiple warp beams (warp beams) may be used to knit first woven fabric layer 120 and second woven fabric layer 140 in some aspects, in particular aspects first woven fabric layer 120 and second woven fabric layer 140 are simultaneously knit with a single warp beam. In some aspects the first woven fabric layer 120 and the second woven fabric layer 140 are such that the twin warp beams are woven simultaneously.

The multi-layer fabric 100 may include more than two woven fabric layers, such as three, four, or more than four woven fabric layers. Additional woven fabric layers may be attached to one or both of first woven fabric layer 120 and second woven fabric layer 140. Accordingly, in some aspects the multilayer fabric 100 includes at least a third woven fabric layer attached to one or both of the first and second woven fabric layers 120, 140. The third knitted fabric layer has a third functionality that is different from one or both of the first functionality and the second functionality.

The multi-layer fabric 100 can have any desired fabric weight. In certain aspects, the fabric has a weight of about 6 to about 16 ounces per square yard (osy). In certain aspects, the multilayer fabric has a weight of about 8 to about 14.5 osy.

Method of forming a multi-layer fabric

Aspects of the present disclosure also relate to methods for forming a multilayer fabric. Referring to fig. 3, method 300 includes, at step 320, weaving first fabric layer 120 on a loom, the first fabric layer 120 having a first functionality. At step 340, second fabric layer 140 is woven on a loom. Second fabric layer 140 has a second functionality that is different from the first functionality. In step 360, second fabric layer 140 is attached 160 to first fabric layer 120 while first fabric layer 120 and second fabric layer 140 are on the loom. In some aspects, while forming first fabric layer 120 and second fabric layer 140 on the loom, step 360 is performed: second fabric layer 140 is attached 160 to first fabric layer 120.

Fig. 4 is a schematic diagram illustrating an exemplary method for forming a multilayer fabric 100 according to aspects of the present disclosure. First fabric layer 120, including weft yarns 125 and warp yarns 130, is woven in an 3/1 twill weave pattern (warp yarns 130(fed) are delivered in a repeating pattern over three of weft yarns 125 and then under one of weft yarns 125). Second fabric layer 140, including weft yarns 145 and warp yarns 150, is woven in the same manner in an 3/1 twill pattern. As shown, the second fabric layer 140 is attached to the first fabric layer 120 by delivering one of the weft yarns 125, attachment yarn 165, of the first fabric layer 120 over the yarns of the second fabric layer 140. In this manner, second fabric layer 140 is eighth (8)^th) Attached 160 to the first fabric layer 120 at the weft yarns (pick). This attachment pattern will result in a multi-layer fabric with longitudinal air pockets, provided that the fabric layers are not also attached in the warp direction (see fig. 2C).

First woven fabric layer 120 and second woven fabric layer 140 of multi-layer fabric 100 may be woven simultaneously on the same loom. Although multiple warp beams may be used to knit the first and second woven fabric layers 120, 140 in some aspects, in particular aspects the first and second woven fabric layers 120, 140 are simultaneously knitted with a single warp beam. In certain aspects, the first woven fabric layer 120 and the second woven fabric layer 140 are woven simultaneously with a double warp beam.

Additional schematic diagrams illustrating exemplary methods for forming a double layer fabric according to aspects of the present disclosure are illustrated in fig. 5A-C. Fig. 5A illustrates a double layer fabric in which upper woven fabric layer 510 is a plain weave pattern and lower woven fabric layer 520 is an 3/1 twill weave pattern. The lower woven fabric layer 520 is attached to the upper woven fabric layer 510 every 4 th yarn/weft.

Fig. 5B illustrates a double layer fabric wherein upper woven fabric layer 530 is an 2/2 twill weave pattern and lower woven fabric layer 540 is a 3/1 twill weave pattern. The lower woven fabric layer 540 is attached to the upper woven fabric layer 530 every 4 th yarn/weft.

Fig. 5C illustrates a double layer fabric wherein upper woven fabric layer 550 is a plain weave pattern and lower woven fabric layer 560 is an 2/2 twill weave pattern. The lower woven fabric layer 540 is attached to the upper woven fabric layer 530 every 4 th yarn/weft.

Additional schematic diagrams illustrating exemplary methods for forming a multilayer fabric according to aspects of the present disclosure are illustrated in fig. 6A and 6B. Fig. 6A illustrates a triple layer, multi-layer fabric wherein upper woven fabric layer 610 is a plain weave pattern, middle woven fabric layer 620 is an 3/1 twill weave pattern, and lower woven fabric layer 630 is a 2/2 twill weave pattern. Every 6 th yarn/weft of lower woven fabric layer 630 is attached to middle woven fabric layer 630 and every 4 th and 9 th yarns/weft of middle woven fabric layer 620 is attached to upper woven fabric layer 610.

Fig. 6B illustrates a four-layer multilayer fabric, where upper woven fabric layer 640 is a plain weave pattern, second woven fabric layer 650 is an 3/1 twill weave pattern, third woven fabric layer 660 is a 2/2 twill weave pattern, and lower woven fabric layer 670 is a 3/1 twill weave pattern. Lower woven fabric layer 670 is attached to third woven fabric layer 660 every 3 rd yarn/weft, third woven fabric layer 660 is attached to second woven fabric layer 650 every 6 th yarn/weft, and second woven fabric layer 650 is attached to upper woven fabric layer 640 every 9 th yarn/weft.

In accordance with the above, the method may therefore in certain aspects comprise weaving more than two fabric layers (e.g. 3, 4, 5, 6, 7 or even 8 fabric layers) on a weaving machine to form a multilayer fabric having from 3 to 8 or more than 8 fabric layers.

The multilayer fabric 100 and woven fabric layers formed according to the methods described herein may have any functionality, yarn type, yarn size, yarn color, fabric construction, weave type, and optionally additional woven fabric layers as described above and will not be described again here.

Article formed from a multi-layer fabric

The multilayer fabrics formed according to the aspects described herein and according to the methods described herein may be useful in a wide range of applications. The multilayer fabric may be particularly useful in garments such as work wear, outerwear, outdoor applications, casual wear, fashion wear, personal protective equipment, and as specialty equipment. In certain aspects, garments formed from multiple layers of fabric include jackets, pants, jeans, hats, shirts, overalls (overall), work clothes, or athletic garments.

In particular aspects, garments including the multi-layer fabrics described herein may be reversible by incorporating different colors and/or textures in the layers of the multi-layer fabric. In one aspect, the front side (layer) of a garment (e.g., denim jeans, coveralls/shirts) may have a first color (e.g., blue) and the back side (layer) may include a second color different from the first color such that the colored back side (layer) is exposed upon rupture of the front side (layer). In yet a further aspect, the back side/layer of the fabric may be multi-colored such that a different colored back side/layer is exposed each time the front side/layer is ruptured. In some aspects, the work garment fabric may be piece-dyed to obtain a multi-layer fabric having the same color (or, in other aspects, different colors).

In another aspect, the garment may include a denim/coverall fabric outer layer and an inner layer comprising bicomponent fibers such as those described herein. The inner layer will expand as it gets wet as described above, while the outer denim/coverall layer will maintain its aesthetic appearance.

In other aspects, the garment may include an outer fabric layer including yarns that provide abrasion, flame, and/or water resistance to the fabric layer (e.g., yarns including para-aramid and/or meta-aramid fibers), and an inner fabric layer including yarns that provide good softness or hand functionality to the fabric layer (e.g., yarns including cotton and/or polyester).

In some aspects it may be desirable to have only one layer of the multi-layer fabric or garment containing the multi-layer fabric be finish treated. For example, a multi-layer fabric including a polyester outer layer and a cotton inner layer may be treated with a Durable Water Repellent (DWR) that adheres only to the polyester outer layer and not to the cotton inner layer.

In still other aspects, a multilayer stretch fabric may comprise: an outer fabric layer comprising yarns having a stretch functionality; and an inner fabric layer comprising yarns having another stretch functionality different from the stretch functionality of the outer fabric layer.

The present disclosure encompasses various combinations of elements of the present disclosure, for example, combinations of elements in dependent claims dependent on the same independent claim.

Disclosure of the invention

In various aspects, the present disclosure relates to and includes at least the following aspects.

Aspect 1: a multilayer fabric comprising at least a first woven fabric layer and a second woven fabric layer attached to the first woven fabric layer, wherein:

the first knitted fabric layer provides a first functionality to the multi-layer fabric;

the second knitted fabric layer provides a second functionality to the multi-layer fabric; and is

The first functionality is different from the second functionality.

Aspect 2: the multilayer fabric according to aspect 1, wherein the first functionality and the second functionality are selected from one or more of the following: warming, cooling, season-long, flame retardancy, antibacterial, odor control, retroreflectivity, ultraviolet protection, abrasion resistance, energy tolerance, water repellency, wind resistance, thermal conductivity, electrical conductivity, stretch, non-stretch, softness, hand feel, nub, fabric smoothness, yarn size, printability, dyeability, color change, style change, responsiveness, energy boost, skin moisturization, Infrared (IR) transmission, IR reflection, IR absorption, ventilation, controlled shrinkage, sensory properties, aesthetic appearance, and aesthetic feel.

Aspect 3: the multilayer fabric according to aspect 1 or 2, wherein the first knitted fabric layer comprises first yarns knitted into a first fabric construction, and the first functionality is provided by one or more of the first yarns and the first fabric construction.

Aspect 4: the multi-layer fabric according to aspect 3, wherein the first yarns weave in the first fabric construction in both the warp and weft directions, and the first yarns that weave in the warp direction and the first yarns that weave in the weft direction comprise the same yarn type or different yarn types.

Aspect 5: the multilayer fabric according to aspect 4, wherein the first functionality is provided by a first yarn woven in a warp direction, a first yarn woven in a weft direction, or a first yarn woven in both the warp and weft directions.

Aspect 6: the multilayer fabric according to any one of aspects 1 to 5, wherein the second knitted fabric layer comprises second yarns knitted into a second fabric construction, and the second functionality is provided by one or more of the second yarns and the second fabric construction.

Aspect 7: the multilayer fabric according to aspect 6, wherein the second yarns are woven in the warp and weft directions into a second fabric construction, and the second yarns woven in the warp direction and the second yarns woven in the weft direction comprise the same yarn type or different yarn types.

Aspect 8: the multilayer fabric according to aspect 7, wherein the second functionality is provided by a second yarn woven in the warp direction, a second yarn woven in the weft direction, or a second yarn in both the warp and weft directions.

Aspect 9: the multilayer fabric according to any one of aspects 4 to 8, wherein the first fabric construction comprises a first weave type and the second fabric construction comprises a second weave type, and the first weave type and the second weave type are independently selected from the group consisting of plain weave, twill weave, satin weave, pile weave, mini-jacquard weave, knit look weave, rip-stop weave, derivatives thereof, and combinations thereof.

Aspect 10: the multilayer fabric according to any one of aspects 6 to 9, wherein the first yarn and the second yarn are independently selected from spun yarn, filament yarn, fancy yarn, bicomponent yarn, core-sheath hybrid yarn, or combinations thereof.

Aspect 11: the multi-layer fabric of aspect 10, wherein the spun yarn comprises a staple fiber selected from the group consisting of cotton, flax, jute, hemp, ramie, bamboo, pineapple, banana, wool, bean, milk, cashmere, silk, kapok, polyester, nylon, polypropylene, acrylic, rayon, cellulose, acetate, viscose, modal, lyocell, para-aramid, meta-aramid, polytetrafluoroethylene, FR cotton, FR polyester, FR nylon, polylactic acid (PLA), poly (trimethylene terephthalate) (PTT), Polybenzimidazole (PBI), conductive fiber, optical fiber, copolymers thereof, blends thereof, and combinations thereof.

Aspect 12: the multilayer fabric according to aspect 10 or 11, wherein the filament yarn comprises fibers selected from the group consisting of polyester, nylon, polyethylene, polypropylene, acrylic, cellulose acetate, viscose, modal, lyocell, meta-aramid, para-aramid, polytetrafluoroethylene, FR polyester, FR nylon, melamine, modacrylic, elastomeric fibers, polylactic acid (PLA), poly (trimethylene terephthalate) (PTT), Polybenzimidazole (PBI), conductive fibers, optical fibers, bicomponent filaments comprising two of these fibers, multicomponent filaments comprising three or more of these fibers, copolymers thereof, blends thereof, and combinations thereof.

Aspect 13: the multilayer fabric according to aspect 10, wherein one or more of the first yarn and the second yarn comprises a bicomponent yarn, and the bicomponent yarn comprises two or more fibers selected from the group consisting of polyester, nylon, cellulose, and acetate.

Aspect 14: the multilayer fabric according to any one of aspects 1 to 13, wherein the second woven fabric layer is attached to the first woven fabric layer in the warp direction, the weft direction, or in both the warp and weft directions.

Aspect 15: the multilayer fabric according to any one of aspects 1 to 14, further comprising an air pocket between the second woven fabric layer and the first woven fabric layer, the air pocket resulting from attachment between the second woven fabric layer and the first woven fabric layer.

Aspect 16: the multilayer fabric according to aspect 15, wherein the air pockets provide thermal insulation to the multilayer fabric.

Aspect 17: the multilayer fabric according to aspect 15 or 16, wherein the attaching is performed in an adjustable pattern such that the air pockets are formed in the multilayer fabric in an adjustable pattern, having an adjustable size.

Aspect 18: the multilayer fabric according to any one of aspects 1 to 17, wherein the first woven fabric layer and the second woven fabric layer are woven simultaneously on the same loom.

Aspect 19: the multilayer fabric according to aspect 18, wherein the first woven fabric layer and the second woven fabric layer are woven simultaneously with a single warp beam or multiple warp beams.

Aspect 20: the multilayer fabric according to any one of aspects 1 to 19, wherein the fabric comprises at least a third woven fabric layer attached to one or both of the first and second woven fabric layers.

Aspect 21: the multilayer fabric according to aspect 20, wherein the third knitted fabric layer has a third functionality, the third functionality being different from one or both of the first functionality and the second functionality.

Aspect 22: a garment formed from the multilayer fabric of any one of aspects 1 to 21.

Aspect 23: a garment according to aspect 22, wherein the garment comprises a jacket, pants, jeans, hat, shirt, gown, coverall, or athletic garment.

Aspect 24: a method of forming a multi-layer fabric comprising:

weaving a first fabric layer on a loom, the first fabric layer having a first functionality;

weaving at least a second fabric layer on the loom, the second fabric layer having a second functionality different from the first functionality; and

attaching the second fabric layer to the first fabric layer while the first fabric layer and the second fabric layer are on the loom.

Aspect 25: the method according to aspect 24, wherein the loom comprises a single warp beam or a plurality of warp beams.

Aspect 26: the method according to aspect 24 or 25, further comprising:

weaving at least a third fabric layer on the loom, the third fabric layer having a third functionality, the third functionality being different from one or both of the first functionality and the second functionality; and

attaching a third fabric layer to one or both of the first fabric layer and the second fabric layer.

Aspect 27: the method according to any one of aspects 24 to 26, wherein the multilayer fabric comprises 2 to 8 woven fabric layers.