Woven textile and method for making a woven textile

Abstract

Woven textiles and methods of making woven textiles provide an increased level of three-dimensional design flexibility without extensive post weaving processing. Textiles are woven to form three-dimensional shaped structures, the shapes corresponding to anatomical and other designed structures. Hollow and/or expandable woven textiles with treads or filaments integrated into the construction, wherein the weft threads pass between or interchange between layers or folded layers, define a predetermined controlled shape and retain overall control of the form and size of the woven textile when expanded.

What is claimed is: 
     
         1 . A process for forming a woven textile comprising:
 passing at least one fill shuttle partially across a width of a textile structure that is oriented in a first dimension, the passing of at least one fill shuttle placing a fill material oriented in a second dimension;   reversing the at least one fill shuttle while continuing the placing of the fill material, the reversing of the at least one fill shuttle doubling the fill material;   securing the fill material to the textile structure with a securement yarn shuttle, the securement yarn oriented in a third dimension, to form a layer; and   repeating the passing the first shuttle, reversing the first shuttle, and securing the filler material to form stacked layers;   wherein the stacked layers form a three-dimensional shape of the woven textile.   
     
     
         2 . A process for forming a woven textile according to  claim 1 , wherein the textile comprises at least two layers, a first layer having a first geometry; and a second layer having a second geometry, the second geometry being different from the first geometry; wherein the first layer and the second layer are formed from a single woven construct. 
     
     
         3 . A process for forming a woven textile having two or more contoured layered dimensions, comprising:
 starting a delivered pick for a contoured layer at a first predetermined edge of a graphic design,   continuously delivering a filling yarn from a shuttle across a predetermined portion of a plurality of warp threads to match a predetermined opposing edge of the graphic design of the contoured layer and reversing the direction of the shuttle to double the first filling yarn to lock the warp layer together, and continuously delivering the filling yarn across the predetermined portion of warp threads to reach the first predetermined edge and exiting the yarn from the warp   repeating the process for each of the additional at least two discrete contoured layers until the desired predetermined fill for each layer has been achieved deploying a supplemental yarn from a warp shuttle to deploy a thread that traverses the at least two contoured layers to bind the warp and weft yarns across the depth of the two layers.   
     
     
         4 . The process for forming a woven textile according to  claim 3 , wherein the supplemental yarn secures the warp and weft yarns using a weave selected from orthogonal, interlock, and layer to layer. 
     
     
         5 . The process for forming a woven textile according to  claim 4 , wherein the placement of the filling yarn is determined by a weave program. 
     
     
         6 . The process for forming a woven textile according to  claim 5 , wherein the weave program is JacqCad. 
     
     
         7 . The process for forming a woven textile according to  claim 3 , wherein the portion of the warp threads across which the fill is delivered in any particular layer is determined by following a profile of a graphic representation of that layer. 
     
     
         8 . The process for forming a woven textile according to  claim 3 , wherein graphic representation is provided by a deconstruction of a three-dimensional profile. 
     
     
         9 . The process for forming a woven textile according to  claim 3 , wherein forming of the woven textile also includes forming edge tie downs. 
     
     
         10 . The process for forming a woven textile according to  claim 9 , wherein forming of the edge tie downs includes overlaying an un-reduced graphic image over a technical cut file. 
     
     
         11 . The process for forming a woven textile according to  claim 3 , the woven textile comprising at least five layers. 
     
     
         12 . The process for forming a woven textile according to  claim 3 , further comprising forming at least one layer over a solid preform positioned on the woven textile adjacent two layers. 
     
     
         13 . A process for forming a woven textile comprising:
 forming a main body;   forming a weft; and   exchanging layers during the forming of the weft, such that exchanging layers forms an unwoven weft between layers of the main body;   wherein the unwoven wefts provide limiters that define a geometry of the woven textile when expanded.   
     
     
         14 . A process for forming a woven textile according to  claim 13 , wherein the woven textile formed by the process comprises a first layer; a second layer; and a weft thread connecting the first layer and the second layer, the weft thread being formed by weaving of the woven textile; wherein the weft thread limits expansion of the woven textile when expanded with a fill material. 
     
     
         15 . The process for forming a woven textile according to  claim 14 , wherein the woven textile formed by the process comprises first and second layers that are formed by folding a continuous woven textile, and wherein the weft thread connecting the layers is a thread that is interchanged between the layers. 
     
     
         16 . The process for forming a woven textile according to  claim 13 , wherein the position of the unwoven supplementary wefts between the layers is reversed on each pass, and the exchange of layers is repeated across a width of the main body of the woven textile, repeatedly reversing the orientation of even and odd supplementary wefts and forming the floating unwoven supplementary wefts, the unwoven supplementary wefts limiting an expansion width of the woven textile when expanded, and wherein optionally the supplementary wefts are controlled with a stop motion to decrease or eliminate interruptions in a density of the main body weave. 
     
     
         17 . A textile composite comprising:
 a textile scaffold formed by weaving, the scaffold comprising one or both of a contoured multilayered textile comprising one or more yarns, and a multilayered textile having at least two layers interconnected by at least one weft thread and comprising at least two internal voids defined by the at least one weft thread, wherein at least two layers of the multilayered textile has a different shape, and wherein the layers are stacked   a binder infused throughout at least a portion of the textile scaffold;   a formable material filling at least one void in the textile scaffold; and   wherein the first layer and the second layer are formed from a single woven construct.   
     
     
         18 . The textile composite according to  claim 17 , wherein the binder is a concrete binder comprising a chemical formulation that is reactive with concrete, and wherein the formable material filling comprises concrete. 
     
     
         19 . The textile composite according to  claim 18 , wherein the binder comprises a cell stimulating material and wherein the formable material comprises living cells. 
     
     
         20 . The textile composite according to  claim 19 , wherein one or more of a yarn forming the textile scaffold, the binder, and the formable material comprises one or more of a biocompatible polymer, a biocompatible metal, and a tissue growth stimulator.