CLOTHING COMPONENTS AND ARTICLES OF CLOTHING INCLUDING FABRIC WOVEN WITH A MULTI-LAYERED REGION AND A SINGLE-LAYERED REGION, AND METHODS OF MAKING SUCH WOVEN FABRICS

Abstract

Components adapted for use in an article of clothing, and articles of clothing including such components, include a woven fabric comprising at least one multi-layered region and at least one single-layered region. The at least one multi-layered region can comprise a first woven fabric layer and a second woven fabric layer that is opposite from the first woven fabric layer, where the first and second woven fabric layers are separated from each other. The at least one multi-layered region and the at least one single-layered region can be weaved from the same sets of warps and wefts to form an integral fabric. Methods of making an item of apparel include forming a woven fabric comprising at least one multi-layered region and at least one single-layered region weaved from the same sets of warps and wefts, and cutting the woven fabric along a predetermined pattern to form one or more components.

Description

TECHNICAL FIELD

The present disclosure relates generally to apparel. More specifically, various embodiments of the present disclosure relate to woven articles of apparel and methods for making woven items of apparel.

BACKGROUND

Conventional items of apparel and garments (e.g., shirts, shoes, pants, jackets, etc.) are typically constructed by cutting a number of different components from one or more desired materials according to predetermined patterns. For example, a woven fabric may be obtained as a desired material, and components can be cut from the woven fabric along predetermined patterns. The various components cut from the one or more desired materials are then typically coupled together in conventional fashion, such as by sewing and/or adhering the various components together.

Often, items of apparel include pockets and/or other openings, such as openings for drawstrings, etc. that may require multiple components to be sewed together, or may require the same component to be sewed to itself. For example, in conventional apparel items, pockets may be formed by sewing two or more components together. Other openings, such as openings for a drawstring, may be formed by folding a portion of a component onto itself and sewing the portion of the component. In addition, items of apparel may also utilize multiple types of material to incorporate various textures or visual effects to the apparel item. For example, an item of apparel may use two or more different types of woven fabric to incorporate various design effects into the apparel item when completed.

In the manufacture of apparel and garments, sewing of pockets, openings and varying types of material can increase the amount of time spent producing each apparel item. By increasing the amount of time spent in production, the cost of production is also increased. Additionally, when two or more components are coupled together, the seams formed by such coupling (e.g., sewing, adhering, etc.) generally represent a weak point in the item, where the apparel or garment is more likely to fail when forces are applied that tend to pull the seams apart.

It would, therefore, be advantageous to provide apparel that can be formed with reduced sewing and fewer seams, while still enabling the apparel to include both functional features such as pockets and other openings, as well as visual features such as differing fabric patterns.

BRIEF SUMMARY

Various embodiments of the present disclosure relate to fabrics woven in a manner to provide various functional and/or ornamental features in a single continuous web, as opposed to separate components being coupled together. According to at least one embodiment of the present disclosure, a component can be adapted for use in an article of clothing, which component may include a woven fabric comprising at least one multi-layered region and at least one single-layered region. The at least one multi-layered region may comprise a first woven fabric layer and a second woven fabric layer that is opposite from the first woven fabric layer, where the first and second woven fabric layers are separated from each other. The woven fabric is configured to change between the at least one multi-layered region and the at least one single-layered region with the same sets of warps and wefts.

Other embodiments of the present disclosure include articles of clothing. According to at least one embodiment, such articles of clothing may comprise a plurality of components coupled together, where at least one component of the plurality of components includes a woven fabric. The woven fabric may include a multi-layered region comprising a first woven fabric layer and a second woven fabric layer, where warps and wefts of the first woven fabric layer are distinct from warps and wefts of the second woven fabric layer. The woven fabric may also include a single-layered region woven from the same groups of warps and wefts used in the first and second woven fabric layers of the multi-layered region.

Additional embodiments of the present disclosure include methods for making an item of apparel. One or more implementations of such methods may include forming a woven fabric. The woven fabric may include at least one multi-layered region comprising a first woven fabric layer and a second woven fabric layer that is opposite from the first woven fabric layer, where the first and second woven fabric layers are separated from each other. The woven fabric may also include at least one single-layered region. The at least one multi-layered region and the at least one single-layered region may be weaved from the same sets of warps and wefts. The woven fabric may be cut along a predetermined pattern to form one or more components from the woven fabric. The one or more components can also be coupled together to form at least a portion of the article of apparel.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

Exemplary embodiments of the disclosure will become more fully apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. Understanding that these drawings depict only exemplary embodiments and are, therefore, not to be considered limiting of the disclosure's scope, the exemplary embodiments of the disclosure will be described with additional specificity and detail through use of the accompanying drawings in which:

FIG. 1 is a cross section view of a woven fabric according to at least one embodiment;

FIG. 2 is top view of a woven fabric illustrating an example of a 3×3 weave pattern according to at least one embodiment;

FIG. 3 is a perspective view of a Jacquard Loom together with at least one embodiment of weaving a woven fabric;

FIG. 4A is a cross-sectioned view of a portion of the Jacquard Loom of FIG. 3 depicting four sets of alternating warp yarns interwoven with a set of weft yarns formed in a single-layered fabric region of a woven fabric;

FIGS. 4B-4G are cross-sectioned views as in FIG. 4A, depicting at least one embodiment of a series of steps to form two opposing layers comprising a multi-layered fabric region of a woven fabric;

FIG. 5 is a plan view of a woven fabric adapted for forming components for use in making a pair of shorts, according to at least one embodiment;

FIG. 6 is a plan view of a woven fabric adapted for forming components for use in making a pair of shoes, according to at least one embodiment;

FIG. 7 is a plan view of a woven fabric adapted for forming various components for use in forming a jacket, according to at least one embodiment;

FIG. 8 is a plan view of a woven fabric adapted for forming various components for use in forming a jacket, according to at least one other embodiment; and

FIG. 9 is a flow diagram illustrating a method for making an item of apparel according to at least one implementation.

DETAILED DESCRIPTION

The illustrations presented herein are, in some instances, not actual views of any particular woven fabric, apparel component or apparel item, but are merely idealized representations which are employed to describe various aspects of the present disclosure. Additionally, elements common between figures may retain the same numerical reference designation.

Various embodiments of the present disclosure relate to woven fabrics for forming components suitable for use, for example, in items of apparel. The woven fabric described herein may comprise a fabric that is woven as a continuous web in such a way that, over selected regions of the fabric, the fabric is woven in two or more layers with the warps and wefts of each layer being distinct from the warps and wefts of the other layer, while in other regions the warps and wefts of the two or more layers are woven together as a single layer. In at least some embodiments, the warps and wefts of the two or more layers can be woven together as a single layer by introducing a pattern of woven stitches in warp and/or weft directions. In one or more other embodiments, the warps and wefts of the two or more layers can be woven together by interweaving the warps of both the layers into a single layer with the same group of wefts and by interweaving the wefts of both layers with the same groups of warps. The fabric thus woven is produced as a continuous web from which individual components of an item of apparel are subsequently formed by cutting the web along predetermined lines.

With reference to the accompanying drawings, FIG. 1 is a cross section view of a woven fabric 100 according to at least one embodiment. For simplicity of discussion, the woven fabric 100 will be discussed in the context of a particular weft pattern, although equally within the scope of this disclosure is the same fabric 100 woven where weft yarns and warp yarns are interchanged in their positions, thus producing a similar fabric 100. Therefore, specific reference to warp or weft yarns in the below discussion should not limit the scope of the woven fabric 100 where warp yarns 110 are interchangeable with weft yarns 120.

One or more warp yarns 110 may be interwoven with one or more weft yarns 120. As displayed, the one or more warp yarns 110 may include four sets of warp yarns 110, including first and second pairs 130, 135 of warp yarn sets. Although single warp yarn threads 110 are shown, each warp yarn thread 110 may represent a single warp yarn comprising a warp yarn set, or a plurality of warp yarns that comprise a warp yarn set. In the actual weaving process of the woven fabric 100, a warp yarn set comprising a plurality of warp yarns may be implemented by positioning each of the warp yarns in the warp yarn set in like manner to its corresponding single warp yarn depicted. Similarly, although only single weft yarns 120 are shown, each weft yarn thread 120 may represent a single weft yarn comprising a weft yarn set, or a plurality of weft yarns that comprise a weft yarn set. Where the weft yarn set comprises a plurality of weft yarns, each of the weft yarns of the weft yarn set can be positioned in like manner to its corresponding single weft yarn depicted. Consequently, the four warp yarns 110 displayed in FIG. 1 can represent four sets of warp yarns 110, where each set comprises one or more warp yarns, and each weft yarn 120 can represent individual sets of weft yarns 120, where each set comprises one or more weft yarns.

FIG. 2 shows an example where warp yarn sets 210a, 210b comprise a plurality of individual warp yarns, and where weft yarn sets 220a, 220b comprise a plurality of individual weft yarns. As shown, the first set of weft yarns 210a form a set of yarns extending at least substantially in parallel, passing over and under the same sets of warp yarns, and the second set of weft yarns 210b also form a set of yarns extending at least substantially in parallel, passing over and under the same sets of warp yarns. Similarly, the first and second sets of warp yarns 220a, 220b form respective sets of yarns which extend at least substantially in parallel, passing over and under the same sets of weft yarns.

Referring again to FIG. 1, it should be noted that the number of yarns in each set of weft yarns and/or warp yarns may vary across the fabric. For example, the weft yarn set 120a may comprise one or more yarns while the weft yarn set 120b comprises a different number of yarns. Furthermore, the number of yarns in a particular set of weft and/or warp yarns may vary at different regions in the fabric. For example, the weft yarn set 120a may comprise one or more yarns in a first region, and then the weft yarn set 120a may comprise a different number of yarns in another region. It is noted, therefore, that the actual number of yarns in any of the various warp and/or weft sets can vary as desired for a particular application.

Referring still to FIG. 1, in at least one embodiment, the first pair 130 of warp yarn sets may include first and second sets 110a, 110b of warp yarns. The second pair 135 of warp yarn sets may include third and fourth sets 110c, 110d of warp yarns. The woven fabric 100 can be woven by creating at least two general fabric regions, a multi-layered fabric region 140, and a single-layered fabric region 150. When the multi-layered fabric region 140 is weaved, first and second pairs 130, 135 of warp yarn sets may alternately correspond to, respectively, first and third sets 110a, 110c of warp yarns, and second and fourth sets 110b, 110d of warp yarns, as will be described hereafter.

The multi-layered fabric region 140 and the single-layered fabric region 150 are weaved from the same sets of warp yarns 110 and weft yarns 120, forming an integral, woven fabric 100. The single-layered region 150 can be weaved with first and second warp yarn sets 110a, 110b woven over a first weft yarn set 120a, while third and fourth warp yarn sets 110c, 110d can be woven under the first weft yarn set 120a. Further, the first and second warp yarn sets 110a, 110b can be woven under a second weft yarn set 120b, while third and fourth warp yarn sets 110c, 110d can be woven under the second weft yarn set 120b. This manner of weaving produces a weaving pattern, which may be repeated to form a desired length of single-layered fabric region 150.

One skilled in the art will appreciate that other ways of alternating weaving warp yarn sets (110a, 110b, 110c, 110d) may create the single-layered fabric region 150, such as by weaving one set of warp yarns over a first weft yarn set 120a while weaving the other three sets of warp yarns (or the remainder of the four sets of warp yarns) under the first weft yarn set 120a. Weaving warp yarn sets around a second weft yarn set 120b could follow the one/three split of warp yarn sets, or change back to weaving first and second pairs 130, 135 of warp yarn sets on either side of subsequent set of weft yarns 120. Furthermore, more than four warp yarn sets may be used. Consequently, there are multiple ways to weave the single-layered fabric region 150, which may result in an integral, single piece of woven fabric.

The multi-layered fabric region 140 may be weaved from the same plurality of warp yarns 110 and weft yarns 120 as used to weave the single-layered fabric region 150. That is, the first warp yarn set 110a can be woven over a third weft yarn set 120c while third warp yarn set 110c is woven under the third weft yarn set 120c. Further, first warp yarn set 110a may be woven under a fourth weft yarn set 120d while third warp yarn set 110c is woven over the fourth weft yarn set 120d. Additionally, second warp yarn set 110b is woven over a fifth weft yarn set 120e while the fourth warp yarn set 110d is woven under the fifth weft yarn set 120d. Further, second warp yarn set 110b is woven under a sixth weft yarn set 120f while fourth warp yarn set 110d is woven over the fifth weft yarn set 120f. This manner of weaving produces a weaving pattern, which may be repeated to form a desired length of multi-layered fabric region 140.

In the embodiment depicted in FIG. 1, the first and third warp yarn sets 110a, 110c are alternately woven around third and fourth weft yarn sets 120c, 120d to form a first woven fabric layer 160. Likewise, the second and fourth warp yarns sets 110b, 110d are alternately woven around fifth and sixth weft yarn sets 120d, 120f to form an opposing, second woven fabric layer 170. The weaving of first and second opposing, woven fabric layers 160, 170 may occur in parallel and concurrently for efficiency, i.e., during a weaving process. To make the multi-layered fabric region 140 of desired length, the weaving of first and second opposing, woven fabric layers 160, 170 is repeated until the desired length is obtained. After the multi-layered fabric region 140 is woven in the weaving process, the weaving can transition to again form a single-layered fabric region 150, as described previously.

FIG. 3 is a perspective view of one embodiment of weaving a fabric 100 with a loom, such as a Jacquard Loom 300 having a plurality of lifting bars 310. As before mentioned, the warp yarns 110 may be interchangeable with the weft yarns 120 in the woven fabric 100. Therefore, although the following embodiment is described with particular configurations of warp yarns 110 about weft yarns 120, other embodiments of the weaving process can include similar configurations of weft yarns 120 about warp yarns 110.

Warp yarns sets 110a, 110b, 110c, 110d are spun from at least one warp yarn spool 320, although multiple warp yarn spools 320 could be used, for instance, one each for warp yarn set pairs 130, 135. Warp yarns 110 are fed into lifting bars 310 of the Jacquard Loom 300. As each set of warp yarns 110 is lifted as directed by a computer or punch card (not shown), a weft yarn spool 330 inserts (or picks) one or more weft yarns 120 through the warp yarn sets 110. Weights (not shown) may be used to batten, or press home, the weft yarns 120 into woven fabric 100, which exits onto a fabric spool 340. The alternation of the warp yarns 110 and weft yarns 120 to produce the woven fabric 100 was explained briefly in reference to FIG. 1. Note that the woven fabric 100, as shown, can comprise various alternating patterns of multi-layered fabric region 140 and single-layered fabric region 150, which may be used to produce items of apparel and/or components for used in items of apparel.

FIGS. 4A-4G display a more detailed set of steps that may be used for weaving a woven fabric 100, according to at least one embodiment. Each of FIGS. 4A-4G show a cross-section view of a portion of a Jacquard Loom 300, depicting four sets (410a, 410b, 410c, 410d) of alternating warp yarns 410 woven around sets of weft yarns 420. FIG. 4A shows the four warp yarn sets interwoven with a first weft yarn set 420a formed in a single-layered fabric region 150. This may provide a starting point before a multi-layered fabric region is woven. As depicted, the first and second warp yarn sets 410a, 410b may be woven over the first weft yarn set 420a and third and fourth warp yarn sets 410c, 410d may be woven under the first weft yarn set 420a. First, second, third, and fourth warp yarn sets 410a, 410b, 410c, 410d may be coupled to corresponding first, second, third, and fourth sets 310a, 310b, 310c, 310d of lifting bars 310 of Jacquard Loom 300.

FIG. 4B shows a first step to weaving a multi-layered fabric region 140 according to one exemplary embodiment. After the third set 310c of lifting bars is raised, the second weft yarn set 420b is inserted through the gap created between first and third warp yarn sets 410a, 410c. The arrows superimposed adjacent first and fourth sets 310a, 310d of lifting bars indicate that these are to be raised in the next step.

FIG. 4C shows the result of raising first and fourth sets 310a, 310d of lifting bars, creating another gap, this time between second and fourth warp yarn sets 410b, 410d, through which is inserted the third weft yarn set 420c. The arrows superimposed adjacent third and fourth sets 310c, 310d of lifting bars indicate that these are to be dropped in the next step.

FIG. 4D shows the result of dropping third and fourth sets 310c, 310d of lifting bars, creating another gap between first and third warp yarns sets 410a, 410c, through which is inserted the fourth weft yarn set 420d. The arrows superimposed adjacent second and third sets 310b, 310c of lifting bars indicate that these are to be raised in the next step.

FIG. 4E shows the result of raising second and third sets 310b, 310c of lifting bars, creating another gap between second and fourth warp yarn sets 410b, 410d, through which is inserted a fifth weft yarn set 420e. The arrows superimposed adjacent first and second sets 310a, 310b of lifting bars indicate that these are to be dropped in the next step.

FIG. 4F shows the result of dropping first and second sets 310a, 310b of lifting bars, creating another gap between first and third warp yarn sets 410a, 410c, through which is inserted a sixth weft yarn set 420f. The arrows superimposed adjacent first and fourth sets 310a, 310d of lifting pairs indicates these are next to be raised.

If the weaving process were to end at this point, FIG. 4G shows the result of six sets of weft yarns 420 having been alternately woven into four warp yarn sets 410 in a parallel weaving process. As displayed, a first woven fabric layer 460 comprises first and third warp yarn sets 410a, 410c. Also, second woven fabric layer 470 comprises second and fourth warp yarn sets 410b, 410d. The exact assigned number of the respective warp yarn sets of first and second woven fabric layers 460, 470 are only exemplary for ease of explanation, and are not meant to provide limitations to the scope of this disclosure. Nevertheless, it should be apparent that first and second woven fabric layers 460, 470 are separated and opposing in relation, thereby forming space there between. The weaving process may continue to form a multi-layered fabric region 140 of desired length, and through the pattern controlled by the computer of a Jacquard Loom 300, may weave at least one, single-layered fabric region 150.

It should be noted that use of one or more of the embodiments of the weaving process herein described enables the weaving of both multi-layered fabric regions 140 and single-layered fabric regions 150 from the same sets of warp yarns (410a, 410b, 410c, 410d) during a continuous weaving process. Note that each of the first and second woven fabric layers 460, 470 may be of varying lengths, if desired, to produce varying dimensions to parts of an apparel component. This may still be accomplished through the same, continuous weaving process by simply continuing to weave one of the first and second woven fabric layers 460, 470 while stopping for a time the weaving of the other of the first and second woven fabric layers 460, 470.

Turning to FIGS. 5-8, various examples of woven fabric configurations are illustrated, which are adapted for generating various components for articles of clothing. FIG. 5 is a plan view of a woven fabric 500 adapted for forming components for use in making a pair of shorts, according to at least one embodiment. As illustrated, the woven fabric 500 is formed comprising at least one single-layered fabric region 502, and one or more multi-layered fabric regions 504a, 504b. The single-layered fabric region 502 may be formed in a manner similar to the single-layered fabric region described above. In the alternative, the single-layered fabric region 502 can comprise two or more layers that are interconnected by woven stitching in warp and/or weft directions. Additionally, the single-layered fabric region 502 can be formed using the same weaving pattern throughout the woven fabric 500, or the singe-layered fabric region 502 can be formed using different weaving patterns in different locations in the woven fabric 500.

The multi-layered fabric regions 504a, 504b can be formed in a manner similar to the multi-layered fabric region described above, with two or more separate layers. The multi-layered fabric region 504a, 504b may provide alternative weaving patterns and design effects in the woven fabric 500, and/or may provide functional features associated with a component in the woven fabric 500. For example, the multi-layered fabric region 504a may be included to provide design elements and visual effects to the woven fabric 500. In the example shown, the multi-layered fabric region 504a comprises two different weave patterns, 506 and 508. The first weave pattern 506 of the multi-layered fabric region 504a can comprise longer “floats” to make the fabric appear more shiny and smooth. A “float” is where one set of yarns passes over or under multiple transversely extending yarns or sets of yarns. For example, in the first weave pattern 506, the weft yarn sets may extend over and under two or more warp yarn sets to provide the longer floats described. The second weave pattern 508 may comprise shorter “floats” and/or varying patterns to provide other textures to the multi-layered fabric region 504a.

In addition to providing design effects to the woven fabric 500, a multi-layered fabric region 504a, 504b may also provide functional features to the woven fabric 500. For example, the multi-layered fabric region 504b can comprise two layers forming an elongated opening or pocket. This pocket between the two layers can be positioned through a portion comprising the waistband of the shorts and can be configured to receive a drawstring there through. In this manner, no additional sewing will be required to form such a drawstring pocket, as it is integrally formed in the woven fabric 500.

When the woven fabric 500 is completed, the two components for the shorts can be cut out along the broken lines 510. As shown, the components can be cut through a portion of the multi-layered fabric region 504b to provide access to the elongated opening through which a drawstring can be disposed. These components can subsequently be coupled together by, for example, sewing the components together to form the desired shorts. It should be apparent that similar features may also be employed in a pair of pants by simply extending out leg portions of the components.

FIG. 6 is a plan view of a woven fabric adapted for forming components for use in making a pair of shoes, according to at least one embodiment. The woven fabric 600 shown in FIG. 6 is adapted to form three components of a shoe, a main upper component 602, a heel component 604 and a tongue component 606. Two sets of components are shown for forming a matching pair of shoes—for left and right feet.

The various components can be formed from a combination of single-layered fabric regions 608 and multi-layered fabric regions 610. In some embodiments, the different fabric regions 608, 610 can be implemented for providing a variety of ornamentation and/or visual effects in a single woven fabric component, as opposed to conventional shoe assemblies using individual components of differently configured fabrics that must be sewn together.

The single-layered fabric region 608 may be formed in a manner similar to the single-layered fabric region described above with reference to FIGS. 1-4. In the alternative, the single-layered fabric region 608 can comprise two or more layers that are interconnected by woven stitching in warp and/or weft directions. Additionally, the single-layered fabric region 608 can be formed using the same weaving pattern throughout the woven fabric 600, or the singe-layered fabric region 608 can be formed using different weaving patterns in different locations in the woven fabric 600.

The multi-layered fabric regions 610 can be formed in a manner similar to the multi-layered fabric region described above with reference to FIGS. 1-4, with two or more separate layers. The multi-layered fabric regions 610 may provide alternative weaving patterns and/or design effects in the woven fabric 600. For example, the multi-layered fabric regions 610 can comprise a plurality of different weave patterns, such as weave patterns 612 and 614. The first weave pattern 612 of the multi-layered fabric region may comprise longer “floats” to make the fabric appear more shiny and smooth, and the second weave pattern 614 may comprise shorter “floats” and/or varying patterns to provide other textures to the multi-layered fabric region 610.

When the woven fabric 600 is completed, the various components for the shoes can be cut out along the broken lines illustrated for each component. These components can subsequently be coupled together by, for example, sewing the components together to form the desired upper portion of a shoe, and the completed upper portion can subsequently be coupled to a sole to complete the shoes.

FIG. 7 is a plan view of a woven fabric adapted for forming various components for use in forming a jacket, according to at least one embodiment. The woven fabric 700 is formed with various single-layered fabric regions 702 and multi-layered fabric regions 704a-704d configured in a manner to obtain various jacket components including a body component 706, two hood components 708 and four sleeve components 710.

The single-layered fabric region 702 may be formed in a manner similar to the single-layered fabric region described above with reference to FIGS. 1-4. In the alternative, the single-layered fabric region 702 can comprise two or more layers that are interconnected by woven stitching in warp and/or weft directions. Additionally, the single-layered fabric region 702 can be formed using the same weaving pattern throughout the woven fabric 700, or the singe-layered fabric region 702 can be formed using different weaving patterns in different locations in the woven fabric 700.

The multi-layered fabric regions 704a-704d can be formed in a manner similar to the multi-layered fabric region described above with reference to FIGS. 1-4, with two or more separate layers. The multi-layered fabric regions 704a-704d may provide alternative weaving patterns and/or design effects in the woven fabric 700, and at least some of the multi-layered fabric regions 704a-704d can be configured to provide functional features to the woven fabric 700. For example, the multi-layered fabric region 704a can comprise two layers adapted to form an elongated opening for receiving a drawstring in hood components 708. Similarly, the multi-layered fabric regions 704b and 704c can also be adapted to form elongated openings for receiving drawstrings in the body component 706 that may be used for tightening the jacket around the a user. The multi-layered fabric regions 704d are examples of features in the woven fabric 700 adapted to be implemented as pockets.

When the woven fabric 700 is completed, the various components for the jacket can be cut out along the broken lines illustrated for each component. These components can subsequently be coupled together by, for example, sewing the components together to form the desired jacket. It is noted that similar components may be modified for making a shirt, sweatshirt, coat, etc.

FIG. 8 is a plan view of a woven fabric adapted for forming various components for use in forming another jacket, according to at least one embodiment. The woven fabric 800 is formed with various single-layered fabric regions 802 and multi-layered fabric regions 804 configured in a manner to obtain various jacket components. The single-layered fabric region 802 may be formed in a manner similar to the single-layered fabric region described above with reference to FIGS. 1-4. In the alternative, the single-layered fabric region 802 can comprise two or more layers that are interconnected by woven stitching in warp and/or weft directions. The single-layered fabric region 802 can be formed using the same weaving pattern throughout the woven fabric 800, or the singe-layered fabric region 802 can be formed using different weaving patterns in different locations in the woven fabric 800.

The multi-layered fabric regions 804 can be formed in a manner similar to the multi-layered fabric region described above with reference to FIGS. 1-4, with two or more separate layers. The multi-layered fabric regions 804 may provide alternative weaving patterns and/or design effects in the woven fabric 800 for providing design elements and visual effects, and at least some of the multi-layered fabric regions 804 can be configured to provide functional features to the woven fabric 800. For example, the multi-layered fabric region 804a can comprise two layers adapted to form an elongated opening for receiving a drawstring in hood components for the jacket. The multi-layered fabric regions 804b are examples of features in the woven fabric 800 adapted to be implemented as pockets.

When the woven fabric 800 is completed, the various components for the jacket can be cut out along the broken lines illustrated for each component. These components can subsequently be coupled together by, for example, sewing the components together to form the desired jacket. It is noted that similar components may be modified for making a shirt, sweatshirt, coat, etc.

Although only a few examples of items of apparel have been shown or identified to provide a general description of various features of the present disclosure, it should be apparent to a person skilled in the art that other items of apparel, as well as variations to the items described can also be formed using fabric formed according to the techniques described herein.

Additional embodiments of the present disclosure relate to methods of making items of apparel which include fabric woven with a single-layered region and a multi-layered region. FIG. 9 is a flow diagram illustrating at least one implementation of a method 900 for making an item of apparel including such fabric, according to at least one implementation. For example, referring to FIGS. 1 and 9, a woven fabric 100 may be formed at step 902. The woven fabric includes at least one multi-layered region 140 and at least one single-layered region 150. Forming the woven fabric 100 to include both a multi-layered region 140 and a single-layered region 150 may include weaving the multi-layered region 140 and the single-layered region 150 from the same sets of warp yarns and weft yarns to form an integral woven fabric.

The multi-layered region 140 comprises a first woven fabric layer 160 and a second woven fabric layer 170 that is opposite from the first woven fabric layer 160, such that the first and second woven fabric layers are separate and distinct from each other. For instance, warps and wefts of the first woven fabric layer 160 are woven separate and distinct from the warps and wefts of the second woven fabric layer 170. According to at least one implementation, the multi-layered region 140 can be formed in a manner similar to the multi-layered fabric region 140 described with reference to FIGS. 4A-4G herein above. Furthermore, according to various implementations, the multi-layered region may comprise the same weave pattern throughout the woven fabric, or the multi-layered region may comprise two or more different weave patterns (e.g., differing float, etc.). In some implementations, the first woven fabric layer 160 may be formed to comprise a length that is different than a length of the second woven fabric layer 170.

The single-layered region 150 may be formed in a manner similar to the single-layered fabric region 150 described above with reference to FIGS. 4A-4G. For instance, the single-layered region 150 can be formed by weaving warps of both the first and second woven fabric layers with the same sets of wefts, and by weaving wefts of both the first and second woven fabric layers with the same sets of warps. In other implementations, the single-layered fabric region 150 can comprise the first and second woven fabric layers interconnected by woven stitching in warp and/or weft directions. According to various implementations, the single-layered region can comprise the same weave pattern throughout the woven fabric, or the single layered region can comprise two or more different weave patterns (e.g., different float, etc.).

At step 904, the woven fabric 100 can be cut along a predetermined pattern to form one or more components therefrom. According to at least some implementations, the components can be cut using conventional fabric cutting means, including scissors, lasers, rotary cutters, knifes, razor blades, etc. With the one or more components cut from the woven fabric 100, the one or more components may be coupled together and/or coupled with other components to form at least a portion of an item of apparel at step 906. By way of example and not limitation, the one or more components can be coupled together and/or with other components to form at least a portion of shorts, pants, shoes, jackets, shirts, sweatshirts, coats, or any other item of apparel.

The various embodiments and implementations of the present disclosure result in fabric components and articles of apparel comprising woven fabric that includes both a single-layered fabric region and a multi-layered fabric region formed integrally as a continuous web. Such features can provide increased strength to apparel features such as pockets and openings, and can reduce the total number of steps in production among other benefits.

Implementations and features of the present disclosure may be embodied in other specific forms without departing from its structures, methods, or other essential characteristics as broadly described herein and claimed hereinafter. The described embodiments are to be considered in all respects only as illustrative, and not restrictive. The scope of the invention is, therefore, indicated by the appended claims, rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope.

Claims

1. A component adapted for use in an article of clothing, the component including a woven fabric comprising:

at least one multi-layered region comprising a first woven fabric layer and a second woven fabric layer that is opposite from the first woven fabric layer, wherein the first and second woven fabric layers are separated from each other; and

at least one single-layered region;

wherein the woven fabric changes between the at least one multi-layered region and the at least one single-layered region with the same sets of warps and wefts.

2. The component of claim 1, wherein warps and wefts of the first woven fabric layer of the at least one multi-layered region are distinct from warps and wefts of the second woven fabric layer of the at least one multi-layered region.

3. The component of claim 1, wherein the at least one single-layered region comprises warps and wefts of the first and second woven fabric layers woven together as a single, woven fabric layer.

4. The component of claim 1, wherein the at least one multi-layered region is configured as an opening in the woven fabric for creating a pocket.

5. The component of claim 1, wherein the at least one multi-layered region is configured as an opening in the woven fabric for receiving a drawstring.

6. The component of claim 1, wherein each set of warps comprises one or more yarns, and each set of wefts comprises one or more yarns.

7. An article of clothing, comprising:

a plurality of components coupled together, wherein at least one component of the plurality of components includes a woven fabric comprising: a multi-layered region comprising a first woven fabric layer and a second woven fabric layer, wherein warps and wefts of the first woven fabric layer are distinct from warps and wefts of the second woven fabric layer; and a single-layered region woven from the same groups of warps and wefts used in the first and second woven fabric layers of the multi-layered region.

8. The article of clothing of claim 7, wherein the single-layered region comprises:

the warps of both the first and second woven fabric layers interwoven into a single layer with the same group of wefts; and

the wefts of both the first and second fabric layers interwoven into a single layer with the same groups of warps.

9. The article of clothing of claim 7, wherein the plurality of components are coupled together to form at least a portion of one of shorts, pants, shoes, a jacket, a shirt, a sweatshirt or a coat.

10. The article of clothing of claim 7, wherein the at least one multi-layered region is configured as an opening in the woven fabric for creating a pocket.

11. The article of clothing of claim 7, wherein the at least one multi-layered region is configured as an opening in the woven fabric for receiving a drawstring.

12. The article of clothing of claim 7, wherein each warp comprises one or more yarns, and each weft comprises one or more yarns.

13. A method of making an item of apparel, the method comprising:

forming a woven fabric including: at least one multi-layered region comprising a first woven fabric layer and a second woven fabric layer that is opposite from the first woven fabric layer, wherein the first and second woven fabric layers are separated from each other; and at least one single-layered region; wherein the at least one multi-layered region and the at least one single-layered region are weaved from the same sets of warps and wefts; and

cutting the woven fabric along a predetermined pattern to form one or more components from the woven fabric.

14. The method of claim 13, wherein forming the woven fabric including at least one multi-layered region comprises:

weaving warps and wefts of the first woven fabric layer; and

weaving warps and wefts of the second woven fabric layer,

wherein the warps and wefts of the first woven fabric layer are woven separate and distinct from the warps and wefts of the second woven fabric layer.

15. The method of claim 13, wherein forming the woven fabric including the at least one multi-layered region comprises:

forming the first woven fabric layer with a length that is different than a length of the second woven fabric layer.

16. The method of claim 13, wherein forming the woven fabric including at least one single-layered region comprises:

weaving warps of both the first and second woven fabric layers with the same sets of wefts; and

weaving wefts of both the first and second woven fabric layers with the same sets of warps.

17. The method of claim 13, wherein each set of warps comprises one or more yarns, and each set of wefts comprises one or more yarns.

18. The method of claim 13, further comprising coupling the one or more components together.

19. The method of claim 13, wherein the at least one multi-layered region is configured as an opening in the woven fabric for creating a pocket.

20. The method of claim 13, wherein the at least one multi-layered region is configured as an opening in the woven fabric for receiving a drawstring.