Zoned Fabric Systems and Methods

Abstract

A garment may include a first woven component, a second woven component, a space between the first and second woven components defining a channel filled with a fill material, and a third woven component extending such that the first and second woven components are woven together where there is no channel. The channel may be filled with a filler material. Multiple channels may be provided such that they form a zoned pattern in the garment.

1 . A method of making a zoned fabric, comprising:
 weaving a first fabric component extending substantially parallel to a shuttle direction of a loom;   weaving a second fabric component extending substantially parallel to a shuttle direction of a loom and spaced from the first fabric component and defining a plurality of channels extending along a plane of the fabric;   weaving a third fabric component extending such that the first and second fabric components are woven together at edges of each of the plurality of channels,   cutting a garment component from the zoned fabric; and   filling the plurality of channels with a filler material,   wherein along the plurality of channels, the first fabric component is exposed only along a first side of the zoned fabric and the second fabric component is exposed only along a second side of the zoned fabric.   
     
     
         2 . (canceled) 
     
     
         3 . The method of  claim 1 , wherein the plurality of channels filled with the filler material form a pattern in a finished garment. 
     
     
         4 . The method of  claim 1 , wherein each of the plurality of channels is a seamless channel. 
     
     
         5 . The method of  claim 1 , wherein the filler material is an insulative material. 
     
     
         6 . The method of  claim 1 , wherein the filler material is padding material. 
     
     
         7 . The method of  claim 1 , further comprising:
 forming a jacket at least in part from the garment component.   
     
     
         8 . The method of  claim 1 , further comprising:
 forming a vest at least in part from the garment component.   
     
     
         9 . The method of  claim 1 , further comprising:
 forming a lower body garment at least in part from the garment component.   
     
     
         10 . The method of  claim 1 , wherein filling the plurality of channels with the filler material includes filling a first channel of the plurality of the channels with a different amount of the filler material than a second channel of the plurality of channels. 
     
     
         11 . The method of  claim 1 , wherein filling the plurality of channels with the filler material includes filling a first channel of the plurality of the channels with a different density than a second channel of the plurality of channels. 
     
     
         12 . The method of  claim 1 , wherein filling the plurality of channels with the filler material includes filling a first channel of the plurality of the channels with a different type of the filler material than a second channel of the plurality of channels.