Multilayer weaving for seamless apparel production

Abstract

The present invention provides a process for making a branched tubal structure, the process including weaving the branched tubal structure in at least four stacked layers. The branched tubal structure includes a first section connected to a second section. The first section includes each of the at least four layers connected in a larger folded tube, and the second section includes sequential pairs of the at least four layers connected in at least two smaller tubes. The process can be used to directly make a seamless pants while eliminating the offcut waste of traditional sewing of pants using a woven textile and pattern.

What is claimed is: 
     
         1 . A process for making a branched tubal structure, the process comprising weaving the branched tubal structure in at least four layers,
 wherein the at least four layers are stacked on a weaving machine,   wherein the branched tubal structure comprises a first section connected to a second section,   wherein the first section comprises each of the at least four layers connected in a larger tube, and   wherein the second section comprises sequential pairs of the at least four layers connected in at least two smaller tubes.   
     
     
         2 . The process of  claim 1 , wherein at least two of the at least four layers are not continuously connected. 
     
     
         3 . The process of  claim 1 , wherein the weaving is selected from the group consisting of shuttle weaving or shuttleless weft insertion system. 
     
     
         4 . The process of  claim 1 , wherein the branched tubal structure is woven using at least one pattern selected from the group consisting of a plain weave and its derivatives; a twill weave and its derivatives; a satin/sateen weave and its derivatives; dobby; or jacquard, and wherein the at least one pattern matches around the larger tube and/or the at least two smaller tubes. 
     
     
         5 . The process of  claim 1 , wherein the at least four layers comprise cotton, linen, silk, wool, hemp, modal, lyocell, rayon, polyester, nylon, spandex fiber, and/or metal fiber. 
     
     
         6 . The process of  claim 1 , wherein the branched tubal structure comprises a piece of apparel, a medical implant, a medical device, a plumbing part, an automotive part, and/or a machine part. 
     
     
         7 . The process of  claim 1 , wherein the at least four layers of the larger tube and the sequential pairs of the at least four layers of the at least two smaller tubes are each connected by one sectionally continuous weft yarn, and wherein the larger tube is woven using at least one shuttle and the at least two smaller tubes are woven using at least two shuttles. 
     
     
         8 . A process for making a bifurcated tubal structure, the process comprising:
 weaving the bifurcated tubal structure in four layers,   wherein the four layers are stacked on a weaving machine,   wherein the bifurcated tubal structure comprises a first section connected to a second section,   wherein the first section comprises each of the four layers connected in a larger tube,   wherein the second section comprises sequential pairs of the four layers connected in two smaller tubes, and wherein the weaving is selected from the group consisting of shuttle weaving or shuttleless weft insertion system.   
     
     
         9 . The process of  claim 8 , wherein at least two of the four layers are not continuously connected. 
     
     
         10 . The process of  claim 8 , wherein the bifurcated tubal structure is woven using at least one pattern selected from the group consisting of a plain weave and its derivatives; a twill weave and its derivatives; a satin/sateen weave and its derivatives; dobby; or jacquard, and wherein the at least one pattern matches around the larger tube and/or at least one of the two smaller tubes. 
     
     
         11 . The process of  claim 8 , wherein the four layers comprise cotton, linen, silk, wool, hemp, modal, lyocell, rayon, polyester, nylon, spandex fiber, and/or metal fiber. 
     
     
         12 . The process of  claim 8 , wherein the bifurcated tubal structure comprises a piece of apparel, a medical implant, a medical device, a plumbing part, an automotive part, and/or a machine part; or wherein the bifurcated tubal structure comprises pants. 
     
     
         13 . The process of  claim 8 , wherein the four layers of the larger tube and the sequential pairs of the four layers of the two smaller tubes are each connected by one sectionally continuous weft yarn, and wherein the larger tube is woven using at least one shuttle and the two smaller tubes are woven using at least two shuttles. 
     
     
         14 . A process for making a bifurcated tubal structure, the process comprising:
 a) setting a warp sheet comprising warp yarns on a weaving machine;   b) dividing the warp yarns between at least 8 harnesses, wherein four sets of warp yarns are distributed among the at least 8 harnesses, and wherein the four sets of warp yarns correspond to four layers of woven fabric, L1, L2, L3, and L4;   c) implementing a first sequence of at least 8 sheds, wherein a first weft yarn is inserted into each of the four layers in a first order that connects the four layers of woven fabric in a larger tube, and
 optionally implementing a modified first sequence of the at least 8 sheds, wherein the first weft yarn is inserted into each of the four layers in a modified first order that connects the four layers of woven fabric in the larger tube and wherein at least two of the four layers are not continuously connected; 
   d) repeating step c) until the larger tube is formed to a first desired length;   e) implementing a second sequence of at least 8 sheds, wherein a second weft yarn is inserted into each of the layers L1 and L2 and a third weft yarn is inserted into each of the layers L3 and L4, in a second order that connects the layers L1 and L2 in a first smaller tube and the layers L3 and L4 in a second smaller tube, and
 optionally implementing a modified second sequence of the at least 8 sheds wherein the second weft yarn is inserted into each of the layers L1 and L2 and a third weft yarn is inserted into each of the layers L3 and L4, in a modified second order that connects the layers L1 and L2 in a first smaller tube, the layers L3 and L4 in a second smaller tube, and wherein the layers L1 and L2 and/or the layers L3 and L4 are not continuously connected; and 
   f) repeating step e) until the first smaller tube and the second smaller tube are a second desired length,   
       wherein the larger tube is folded while on the weaving machine, 
       wherein the first smaller tube and the second smaller tube are staked while on the weaving machine, 
       wherein a movement of the at least 8 harnesses in step c) is set by the first sequence of the at least 8 sheds and optionally the modified first sequence of the at least 8 sheds, and the movement of the at least 8 harnesses in step e) is set by the second sequence of at least 8 sheds and optionally by the modified second sequence of the at least 8 sheds, and 
       wherein the larger tube is connected to the first smaller tube and the second smaller tube. 
     
     
         15 . The process of  claim 14 , wherein steps e) through f) are performed before steps c) through d). 
     
     
         16 . The process of  claim 14 , wherein the bifurcated tubal structure is woven using at least one pattern selected from the group consisting of a plain weave and its derivatives; a twill weave and its derivatives; a satin/sateen weave and its derivatives; dobby; or jacquard, and
 wherein the at least one pattern matches around the larger tube, the first smaller tube, and/or the second smaller tube.   
     
     
         17 . The process of  claim 14 , wherein the warp yarns, the first weft yarn, the second weft yarn, and the third weft yarn comprises cotton, linen, silk, wool, hemp, modal, lyocell, rayon, polyester, nylon, spandex fiber, and/or metal fiber. 
     
     
         18 . The process of  claim 14 , wherein the bifurcated tubal structure forms a piece of apparel, a medical implant, a medical device, a plumbing part, an automotive part, and/or a machine part. 
     
     
         19 . The process of  claim 14 , wherein at least one first shuttle is used to insert the first weft yarn in step c), and
 wherein at least one second shuttle is used to insert the second weft yarn and at least one third shuttle is used to insert the third weft yarn in step e).   
     
     
         20 . The process of  claim 19 , wherein the first weft yarn and the second weft yarn are continuous or wherein the first weft yarn and the third weft yarn are continuous.