Engineered woven fabric and article of clothing including same

Abstract

Examples of an article of clothing including an engineered woven fabric are described. An article of clothing includes a single-layer woven portion and a double-layer woven portion seamlessly joined to the single-layer woven portion to form a pocket. The pocket includes a closed side edge and an opening, the closed side edge seamlessly engaged with the single-layer woven portion. The single layer woven portion is designed to include a first tensile modulus zone having a first level of stretchability and a second tensile modulus zone having a second level of stretchability such that the first level of stretchability is greater than the second level of stretchability. A second tensile modulus region is positioned around the closed edge of the pocket to provide support around the pocket.

Description

Technical Field

[0001] This embodiment relates to clothing, and more particularly to clothing including engineered woven fabric having a pocket bag seamlessly woven therein. Background Art

[0002] Typically, pocket bags in clothing are designed and constructed by cutting fabric pieces and sewing them to the clothing, which requires additional fabric to form the pocket bag. The cutting and sewing process is time-consuming, increases fabric waste, and the resulting pocket bags may not be appealing to the user of the clothing as they may appear bulky, saggy, or distracting.

[0003] There is a need in the art for clothing formed with reduced sewing while still including a double-layer structure such as a pocket bag. Summary of the Invention

[0004] In one aspect, the present disclosure provides an article of clothing including an engineered woven fabric. The engineered woven fabric includes a single-layer woven portion having at least one warp yarn and at least one weft yarn. The single-layer woven portion is designed to include a first tensile modulus region having a first stretchability level and a second tensile modulus region having a second stretchability level. The first stretchability level is greater than the second stretchability level. The engineered woven fabric further includes a double-layer woven portion that is seamlessly joined to the single-layer woven portion, and the double-layer woven portion has two independent woven layers, each woven layer having at least one warp yarn and at least one weft yarn. The double-layer woven portion forms a pocket having a closed edge and an opening that are seamlessly joined to the single-layer woven portion. The single-layer woven portion is designed such that the second tensile modulus region is disposed around the closed edge of the pocket to provide support around the pocket.

[0005] In another aspect, the present disclosure provides a clothing article that includes an engineered woven fabric. The engineered woven fabric includes a pocket formed in the engineered woven fabric. The pocket has a plurality of closed edges and a free edge, the plurality of closed edges being disposed around an outer perimeter of the pocket, and the free edge providing an opening into a cavity of the pocket. The engineered woven fabric further includes a surrounding portion of the engineered woven fabric that surrounds at least two of the plurality of closed edges around the outer perimeter of the pocket. The engineered woven fabric further includes at least one additional portion of the engineered woven fabric that surrounds the surrounding portion. The at least one additional portion of the engineered woven fabric includes a first tensile modulus zone having a first level of stretchability, and the surrounding portion includes a second tensile modulus zone having a second level of stretchability. The second level of stretchability is less than the first level of stretchability to provide support around the pocket.

[0006] In another aspect, the present disclosure provides a method of forming a clothing article that includes an engineered woven fabric having a seamless pocket. The method includes weaving an engineered woven fabric having: (1) a single-layer woven portion having at least one warp yarn and at least one weft yarn; and (2) a double-layer woven portion having two independently woven layers, each woven layer having at least one warp yarn and at least one weft yarn. The double-layer woven portion is seamlessly joined with the single-layer woven portion during the weaving process. The method of weaving the single-layer woven portion further includes: weaving a first tensile modulus zone having a first level of stretchability in a first portion of the engineered woven fabric; and weaving a second tensile modulus zone having a second level of stretchability in a second portion of the engineered woven fabric. The first level of stretchability is greater than the second level of stretchability. The method of weaving the double-layer woven portion further includes forming a pocket in the engineered woven fabric, wherein closed edges extend around an outer perimeter of the pocket. The closed edges are seamlessly joined with the single-layer woven portion. The method further includes cutting one of the two independently woven layers along one of the closed edges that extends around the outer perimeter of the pocket to separate the one woven layer and form a free edge. The free edge provides an opening into a cavity formed between the two independently woven layers of the pocket.

[0007] Other systems, methods, features, and advantages of the present disclosure will be or will become apparent to one with skill in the art upon examination of the following figures and detailed description. All such additional systems, methods, features, and advantages are intended to be included within this specification and this summary, are within the scope of the present disclosure, and are protected by the accompanying claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The present disclosure may be better understood with reference to the following drawings and description. Throughout the drawings, reference numerals may be repeated to indicate corresponding relationships between the elements being referenced. The drawings are provided to illustrate exemplary embodiments described herein and are not intended to limit the scope of the present disclosure. The dimensions and relative positions of the elements in the drawings are not necessarily drawn to scale. For example, the shapes and dimensions of the various elements and angles are not drawn to scale, and some of these elements are arbitrarily enlarged and positioned to improve the readability of the drawing.

[0009] Figure 1 is a schematic view of an exemplary embodiment of a portion of a clothing article including an engineered woven fabric having a pocket;

[0010] Figure 2 is an enlarged schematic view of an exemplary embodiment of a pocket seamlessly formed in an engineered woven fabric of a clothing article;

[0011] Figure 3 is along Figure 2 a schematic cross-sectional view of a pocket seamlessly formed in an engineered woven fabric taken along the line shown in

[0012] Figure 4 is a schematic view of an exemplary embodiment of a portion of a clothing article including an engineered woven fabric having a pocket and having different stretch modulus regions;

[0013] Figure 5 is an enlarged schematic view of an exemplary embodiment of a pocket formed in an engineered woven fabric and surrounded by different stretch modulus regions;

[0014] Figure 6 is an enlarged representative view of a process for seamlessly forming an opening in a pocket in an engineered woven fabric;

[0015] Figures 7A to 7C illustrates an exemplary embodiment of a process for seamlessly forming an opening in a pocket in an engineered woven fabric;

[0016] Figure 8A is an alternative embodiment of an arrangement for forming a pocket in an engineered woven fabric;

[0017] Figure 8B is another alternative embodiment of an arrangement for forming a pocket in an engineered woven fabric;

[0018] Figure 8C is another alternative embodiment of an arrangement for forming a pocket in an engineered woven fabric; and

[0019] Figures 9A to 9E illustrates an exemplary embodiment of a clothing article including an engineered woven fabric having a pocket. Detailed implementation mode

[0020] This document describes a clothing article having a pocket seamlessly woven into an engineered woven fabric. The technology of embodiments of the present invention provides an engineered woven fabric and a clothing article made from the engineered woven fabric. In various embodiments, a clothing article is provided having a pocket or pocket lining seamlessly integrated into the article, thereby minimizing fabric waste and visual distraction.

[0021] In the following description, details are set forth to provide an understanding of the present application. In some cases, certain structures, technologies, and methods are not described or shown in detail so as not to obscure the present application. In the context of the present disclosure, these terms are used according to their ordinary meanings understood as various terms.

[0022] For consistency and convenience, directional adjectives are employed throughout the detailed description corresponding to the illustrated embodiments. It should be understood that each of these directional adjectives can be applied to a garment or clothing article, as well as to individual components of the clothing article or garment. Directional terms such as "top", "bottom", "front", "back", "upper", "lower", "outer", and "inner" are used in the following description for the sole purpose of providing relative reference and are not intended to impose any limitation on how any article or garment is positioned during use or how it is mounted in a component or relative to the environment. When used in conjunction with the term "comprising" herein, the use of the word "a" or "an" can mean "one", but it is also consistent with the meanings of "one or more", "at least one", and "one or more than one". Any element expressed in the singular form also encompasses its plural form. Any element expressed in the plural form also encompasses its singular form. The term "plurality" as used herein means more than one, such as two or more, three or more, four or more, etc.

[0023] This document describes a clothing article made from a woven fabric and a method of manufacturing such an article. The woven fabric or textile is made by interlacing warp yarns and weft yarns using a weaving machine or loom. The warp yarns extend vertically through the fabric, and the weft yarns extend horizontally through the fabric. In the context of the present disclosure, the term "seamless" defines a smooth fabric surface and there is no seam or distinct junction between one part or section and the next. Thus, the parts or sections of the seamless woven fabric are formed in the same weaving process and are not separate pieces joined together after being woven individually.

[0024] Figure 1An exemplary embodiment of a clothing article 100 (also referred to herein as "article 100") is shown. For clarity, the following detailed description discusses an exemplary embodiment of a vest-form garment or clothing article, but it should be noted that the techniques described herein can be applied to any form of clothing article or garment, including but not limited to: jackets, coats, shirts, pants, shorts, skirts, dresses, footwear, and other types of clothing or garments.

[0025] Now referring to Figure 1 , the front side 102 of article 100 is shown. In some embodiments, article 100 may have a first side portion 104 associated with a first lateral side 10 and a second side portion 106 associated with a second lateral side 20. In the exemplary embodiment, when article 100 is worn by a wearer, the first lateral side 10 corresponds to the right side of article 100, while the second lateral side 20 corresponds to the reverse left side of article 100. In this embodiment, the first side portion 104 and the second side portion 106 are separated by a fastener in the form of a zipper 108 that extends vertically downward from the collar to the hem along the front side 102 of article 100.

[0026] According to the techniques of this embodiment, article 100 may be provided with one or more pockets seamlessly integrated into the woven fabric forming article 100. In the exemplary embodiment, article 100 may include a first pocket 110 and a second pocket 112, the first pocket 110 being seamlessly formed into the woven fabric of the first side portion 104 on the first lateral side 10, and the second pocket 112 being seamlessly formed into the woven fabric of the second side portion 106 on the second lateral side 20. In some embodiments, the pockets 110, 112 provided on article 100 may be in the form of pouches or pocket linings configured as cavities or void spaces to hold or carry items or objects within the cavity or void space of the pocket. In other embodiments, the pockets 110, 112 may be in the form of cavities or void spaces within article 100 to accommodate the hands of the article wearer. In additional embodiments, the pockets 110, 112 may accommodate the items and / or hands of the wearer of article 100.

[0027] In the exemplary embodiment, the first pocket 110 and the second pocket 112 are arranged on article 100 with the openings facing the lateral sides of article 100. As Figure 1As shown, the opening 114 of the first pocket 110 faces the first lateral side 10, and the opening 116 of the second pocket 112 faces the second lateral side 20. In this embodiment, the openings 114, 116 are configured to receive the hands of the wearer of the article 100 and can also be used as pouches or pockets for storing items or objects. For example, in one embodiment, the size and dimensions of the pockets 110, 112 can be designed to accommodate items or objects such as mobile phones, wallets, keys, sunglasses, and other items or objects of similar size. In other embodiments, the pockets 110, 112 or additional pockets on the article 100 may have larger or smaller sizes and dimensions to accommodate other sized items or objects.

[0028] In some embodiments, one or more pockets on the article 100 (including the first pocket 110 and / or the second pocket 112) may have a closure system that allows the wearer of the article 100 to close and secure the opening of the pocket so that any items or objects therein are ensured to remain inside the pocket. In this embodiment, the first pocket 110 has a first closure system 118 associated with the opening 114, and the second pocket 112 has a second closure system 120 associated with the opening 116. In one embodiment, the first closure system 118 and the second closure system 120 can be in the form of zippers that can be moved back and forth to open and close each of the openings 114, 116 of the pockets 110, 112.

[0029] In other embodiments, the first closure system 118 and / or the second closure system 120 can be other types of fasteners, including but not limited to hook-and-loop fasteners, buttons, snap fasteners, magnets, or other mechanisms that can be used to open and close the openings 114, 116. In additional embodiments, the pockets 110, 112 may not include any closure system for the openings 114, 116. For the sake of illustration, the first closure system 118 and the second closure system 120 are omitted from the remaining figures.

[0030] Now referring Figure 2 , a magnified schematic view of an exemplary embodiment of the first pocket 110 is shown, which is seamlessly formed in the engineered woven fabric of the clothing article 100. In some embodiments, one or more pockets formed in the engineered woven fabric of the clothing article 100 may have a generally rectangular shape. In the exemplary embodiment, the first pocket 110 has an outer perimeter 200 defined by four edges, including a first edge 202, a second edge 204, a third edge 206, and a fourth edge 208. In this embodiment, the outer perimeter 200 of the first pocket 110 has a generally rectangular or square shape. In other embodiments, one or more pockets of the article 100 (including the first pocket 110 and / or the second pocket 112) may have different shapes, including but not limited to Figures 8A to 8CThe shapes shown and other shapes.

[0031] According to the techniques described herein, in some embodiments, a pocket is seamlessly formed in the engineered woven fabric of the article 100 by weaving a portion of the woven fabric in a two-layer or bilayer configuration. That is, while other portions of the article 100 may be formed of a single-layer woven fabric, in one or more portions of the article 100 corresponding to the location of the pockets (including the first pocket 110 and / or the second pocket 112), the woven fabric has a bilayer configuration. With this arrangement, a cavity or void space located between the two layers of the woven fabric forms the pocket (e.g., the first pocket 110 and / or the second pocket 112).

[0032] As Figure 2 shown, the first pocket 110 includes an opening 114 located along a fourth edge 208 of the outer perimeter 200. In an exemplary embodiment, the opening 114 is formed by separating a portion of the two layers that form the first pocket 110 such that one layer remains connected along the entire outer perimeter 200 and the other layer is separated from the second layer along one edge of the outer perimeter 200 (e.g., the fourth edge 208) to produce a free edge 210. In this embodiment, the free edge 210 is generally parallel to the fourth edge 208 and is separated from the woven fabric forming the article 100 to provide access through the opening 114 to the cavity or void space of the first pocket 110 located between the two layers of the woven fabric.

[0033] Figure 3 is a Figure 2 schematic cross-sectional view of the first pocket 110 seamlessly formed in the engineered woven fabric taken along the line shown. In an exemplary embodiment, the first pocket 110 is seamlessly formed in the engineered woven fabric forming the article 100 by weaving a bilayer woven portion having two independent woven layers, each independent woven layer having at least one warp yarn and at least one weft yarn. The bilayer woven portion forms a pocket (e.g., the first pocket 110) having an opening (e.g., the opening 114) along one edge and a closed edge around the remaining outer perimeter that is seamlessly joined to the single-layer woven portion of the engineered woven fabric.

[0034] As Figure 3 shown, the first pocket 110 includes a cavity or void space 300 located between the bilayer woven portion of the engineered woven fabric formed by the first woven layer 302 and the second woven layer 304. In this embodiment, the first woven layer 302 is located on one side of the cavity 300 and the second woven layer 304 is located on the opposite side of the cavity 300. In some embodiments, the bilayer woven portion including the first woven layer 302 and the second woven layer 304 includes two or more warp yarns and two or more weft yarns.

[0035] In an exemplary embodiment, one of the first woven layer 302 and the second woven layer 304 includes a free edge that is separated from the remainder of the engineered woven fabric to provide an opening 114 that permits access to the cavity or void space 300 of the first pocket 110. That is, while the remainder of the outer perimeter of the first pocket 110 includes a closed edge that is seamlessly joined to the surrounding single-layer woven portion, one edge of the first pocket 110 is not closed (i.e., is free or open), such that it remains separate or independent from the surrounding single-layer woven portion.

[0036] In this embodiment, the free edge 210 is disposed at one end of the first woven layer 302 to provide an opening 114 that permits access to the cavity or void space 300 of the first pocket 110. For example, the free edge 210 may be moved outwardly away from the second woven layer 304 to provide an opening 114 that permits the hand of the wearer of the article 100, as well as an item or object, to enter into the cavity 300 of the first pocket 110. At the end 306 of the first woven layer 302 that is opposite the free edge 210, the first woven layer 302 and the second woven layer 304 are seamlessly joined to the single-layer woven portion 308.

[0037] In some embodiments, the clothing article may be formed from an engineered woven fabric having regions of different tensile moduli in portions of the fabric to provide different amounts of stretch resistance and support to the clothing article. According to the techniques of the exemplary embodiments described herein, the clothing article may be made from an engineered woven fabric having one or more pockets seamlessly integrated into the woven fabric, and the pockets may be surrounded by one or more regions of different tensile moduli in portions of the woven fabric. With this arrangement, the article may have a smooth visual appearance and may also provide support to enhance the pockets.

[0038] Now referring to Figure 4 , an exemplary embodiment is shown of a portion of a clothing article 400 including an engineered woven fabric having pockets and having regions of different tensile moduli. In some embodiments, the front side 402 of the article 400 may have a first side portion 404 associated with the first lateral side 10 and a second side portion 406 associated with the second lateral side 20. In this embodiment, the first side portion 404 and the second side portion 406 are separated by a fastener in the form of a zipper 408 that extends vertically downward from the collar 410 along the front side 102 of the article 100 to the hem 412.

[0039] In an exemplary embodiment, the article 400 may include a first pocket 110 and a second pocket 112, the first pocket 110 being seamlessly formed into the woven fabric of a first side portion 404 on a first lateral side 10, and the second pocket 112 being seamlessly formed into the woven fabric of a second side portion 406 on a second lateral side 20. As described above, by weaving a double-layer woven portion having two independent woven layers, the first pocket 110 and the second pocket 112 are seamlessly formed in the engineered woven fabric of the article 400, the two independent woven layers having an opening along one edge (e.g., the opening 114 of the first pocket 110 and the opening 116 of the second pocket 112) and a closed edge surrounding the remaining outer perimeter, the closed edge being seamlessly joined to the single-layer woven portion of the engineered woven fabric of the article 400.

[0040] In some embodiments, the single-layer woven portion of the engineered woven fabric of the article 400 may be provided with various tensile modulus zones that are formed during the weaving process to have different amounts or degrees of stretch (i.e., stretchability). In some cases, different weaving patterns or techniques (e.g., plain weave, pile weave, twill weave, etc.) or different weaving styles (e.g., tight weave or loose weave) may be used to form different tensile modulus zones to provide different amounts or degrees of stretch. For example, some portions of the engineered woven fabric of the article 400 may be tightly woven (less space between the threads), while other portions may be less tightly woven (more space between the threads). In some embodiments, different combinations of weaving patterns / techniques and weaving styles may be used to form various tensile modulus zones. In other cases, different tensile modulus zones may be formed using different yarns formed of materials having different amounts or degrees of stretch. In additional cases, different weaving patterns or techniques and yarns or different materials may be used in combination to provide different tensile modulus zones.

[0041] In an exemplary embodiment, most of the front side 402 of the article 400 may be formed by a single-layer woven portion of an engineered woven fabric, including portions or sections of a first side portion 404 and a second side portion 406. On the first side portion 404, a first upper portion 414 extends from the collar 410 in a downward direction toward the hem 412. The first upper portion 414 is associated with a tensile modulus zone 418 having a level of stretchability. The first side portion 404 also includes a first lower portion 416 that extends from the hem 412 in an upward direction toward the collar 410. The first lower portion 416 is associated with a tensile modulus zone 420 having a level of stretchability. In some embodiments, the tensile modulus zone 418 of the first upper portion 414 may be different from the tensile modulus zone 420 of the first lower portion 416 such that they have different levels of stretchability. In other embodiments, the tensile modulus zone 418 of the first upper portion 414 may have the same level of stretchability as the tensile modulus zone 420 of the first lower portion 416.

[0042] Similarly, on the second side portion 406, a second upper portion 422 extends from the collar 410 in a downward direction toward the hem 412. The second upper portion 422 is associated with a tensile modulus zone 426 having a level of stretchability. The second side portion 406 also includes a second lower portion 424 that extends from the hem 412 in an upward direction toward the collar 410. The second lower portion 424 is associated with a tensile modulus zone 428 having a level of stretchability. In some embodiments, the tensile modulus zone 426 of the second upper portion 422 may be different from the tensile modulus zone 428 of the second lower portion 424 such that they have different levels of stretchability. In other embodiments, the tensile modulus zone 426 of the second upper portion 422 may have the same level of stretchability as the tensile modulus zone 428 of the second lower portion 424.

[0043] Additionally, in some embodiments, the level of stretchability may be the same on similar portions or sections of the article 400 such that the tensile modulus zone 418 of the first upper portion 414 on the first side portion 404 may have the same level of stretchability as the tensile modulus zone 426 of the second upper portion 422 on the second side portion 406. Similarly, the tensile modulus zone 420 of the first lower portion 416 on the first side portion 404 may have the same level of stretchability as the tensile modulus zone 428 of the second lower portion 424 on the second side portion 406.

[0044] In other embodiments, the level of stretchability can be different over similar portions or sections of the article 400 such that the modulus of stretch region 418 of the first upper portion 414 on the first side portion 404 is different from the modulus of stretch region 426 of the second upper portion 422 on the second side portion 406 such that they have different levels of stretchability. Similarly, the modulus of stretch region 420 of the first lower portion 416 on the first side portion 404 can be different from the modulus of stretch region 428 of the second lower portion 424 on the second side portion 406 such that they have different levels of stretchability.

[0045] The single layer woven portion of the engineered woven fabric forming the article 400 also includes portions or sections directly surrounding each of the first pocket 110 on the first side portion 404 and the second pocket 112 on the second side portion 406. As Figure 4 shown, the first surrounding portion 430 is disposed around the edge of the first pocket 110 on the first side portion 404 and the second surrounding portion 434 is disposed around the edge of the second pocket 112 on the second side portion 406. In an exemplary embodiment, the first surrounding portion 430 is associated with a modulus of stretch region 432 having a level of stretchability and the second surrounding portion 434 is associated with a modulus of stretch region 436 having a level of stretchability.

[0046] In an exemplary embodiment, the modulus of stretch region 432 of the first surrounding portion 430 can have the same level of stretchability as the modulus of stretch region 436 of the second surrounding portion 434. However, in other embodiments, the modulus of stretch region 432 of the first surrounding portion 430 on the first side portion 404 can be different from the modulus of stretch region 436 of the second surrounding portion 434 on the second side portion 406 such that they have different levels of stretchability.

[0047] According to the techniques described herein, one or more of the modulus of stretch regions in different portions or sections of the engineered woven fabric of the garment article 400 can have different levels of stretchability. In an exemplary embodiment, one or more of the modulus of stretch regions 418 of the first upper portion 414, the modulus of stretch regions 420 of the first lower portion 416, the modulus of stretch regions 426 of the second upper portion 422, and the modulus of stretch regions 428 of the second lower portion 424 can be a first modulus of stretch region having a first level of stretchability. One or more of the modulus of stretch regions 432 of the first surrounding portion 430 and the modulus of stretch regions 436 of the second surrounding portion 434 can be a second modulus of stretch region having a second level of stretchability. In some embodiments, the first level of stretchability is greater than the second level of stretchability such that the portion or section of the article 400 corresponding to the first modulus of stretch region stretches a greater amount or degree than the portion or section of the article 400 corresponding to the second modulus of stretch region.

[0048] With this arrangement, a second stretch modulus region having a lower stretchability level is provided around the edges of the pockets in the article 400 (e.g., a first circumferential portion 430 extending around the edge of the first pocket 110 and a second circumferential portion 434 extending around the edge of the second pocket 112) to provide support to the pockets and resist stretching to the same amount or degree as the remaining portion or section of the article 400 associated with the first stretch modulus region having a higher stretchability level (e.g., the first upper portion 414, the first lower portion 416, the second upper portion 422, and / or the second lower portion 424). By providing a lesser amount or degree of stretch to the portions or sections of the article 400 immediately surrounding the pockets 110, 112, the article 400 can have a smoother overall appearance and can resist or prevent the pockets 110, 112 from bulging or sagging when carrying items or objects.

[0049] In some embodiments, the stretchability level of the entire single-layer woven portion of the engineered woven fabric forming the article 400 can be less than the stretchability level of the double-layer woven portions forming each of the first pocket 110 and the second pocket 112. With this arrangement, the double-layer woven portions forming each of the first pocket 110 and the second pocket 112 can be stretched to a greater extent than the single-layer woven portion of the engineered woven fabric forming the article 400 to allow or assist in opening the first pocket 110 and the second pocket 112.

[0050] Additionally, in some embodiments, the stretchability level of each layer of the double-layer woven portions forming the first pocket 110 and the second pocket 112 can vary. For example, for each of the first pocket 110 and the second pocket 112, the first layer of the double-layer woven portion can form the front layer of the pocket (e.g., associated with the exterior of the article 400), and the second layer can form the opposite back layer of the pocket (e.g., associated with the interior of the article 400). In an exemplary embodiment, each of these front and back layers can have a different stretchability level.

[0051] In one embodiment, the stretchability levels of the front and back layers of the pocket can be changed by varying the yarn density of each layer during the weaving process of forming the article 400. For example, when one-quarter (1 / 4) of the total number of yarns forming the article 400 is used to form the front layer and the remaining three-quarters (3 / 4) of the total number of yarns is used to form the back layer, this variation in the yarn density between the front and back layers of the pocket will allow the front layer to be stretched to a greater extent than the back layer. Similar techniques can be used to vary the stretchability of one or more double-layer woven portions of the article 400, which one or more double-layer woven portions can be located in different regions or extend through a greater portion of the article 400 than the first pocket 110 and the second pocket 112.

[0052] In some embodiments, the second tensile modulus zone can be woven as a non-tensile zone to substantially prevent stretching. In other embodiments, the second tensile modulus zone can be woven using a reverse twill weave pattern or technique. In additional embodiments, the second tensile modulus zone can be woven using a plain weave pattern or technique. In some embodiments, the first tensile modulus zone can be woven using a regular twill weave pattern or technique. In other embodiments, the first tensile modulus zone can be woven using a ripstop weave pattern or technique. In additional embodiments, the first tensile modulus zone can be woven using elastic fiber yarns. For example, elastic fiber yarns can be added in the warp direction and / or the weft direction of a portion or section of the article 400 associated with the first tensile modulus zone.

[0053] Additionally, in some embodiments, each individual woven layer of a double-woven portion (e.g., Figure 3 the first woven layer 302 and the second woven layer 304 of the first pocket 110 shown) can also be formed with different tensile modulus zones. For example, in one embodiment, the tensile modulus zone of one woven layer of the double-woven portion can be different from the tensile modulus zone of the other woven layer of the double-woven portion. In some cases, the stretchability level of one of the tensile modulus zones of the double-woven portion can be higher than the stretchability level of the opposite layer. That is, one woven layer of the double-woven portion can be stretched to a greater amount or degree than the other woven layer. In one embodiment, one woven layer can be made to have no tensile modulus zone (i.e., substantially prevent stretching), while the other woven layer can be made to have a certain amount or degree of stretch, for example, by incorporating elastic fiber yarns or other suitable materials that exhibit a certain amount or percentage of stretch.

[0054] Now referring to Figure 5 , an enlarged schematic view of an exemplary embodiment of a pocket 110 formed in an engineered woven fabric of an article 400 is shown, the pocket being surrounded by different tensile modulus zones. In the exemplary embodiment, the first pocket 110 includes an outer perimeter 200 defined by four edges, including a first edge 202, a second edge 204, a third edge 206, and a fourth edge 208, as described above. In this embodiment, three of the four edges of the first pocket 110 are closed edges that are seamlessly joined to the surrounding woven fabric of the article 400 (i.e., the first edge 202, the second edge 204, and the third edge 206). The double-woven portion forming the first pocket 110 includes a remaining edge (i.e., the fourth edge 208) that has an open woven layer (i.e., the free edge 210) to provide an opening 114 into the cavity or void space of the first pocket 110.

[0055] In one embodiment, the double - woven portion forming the first pocket 110 is formed by weaving using a first weave pattern 500. In an exemplary embodiment, the first weave pattern 500 can be a plain weave pattern or technique. In other embodiments, the first weave pattern 500 can be another type of weaving pattern or technique. The double - woven first pocket 110 formed using the first weave pattern 500 is surrounded by a single - woven portion forming a first surrounding portion 430 on at least three sides. In an exemplary embodiment, the first surrounding portion 430 includes an outer perimeter spaced apart from the outer perimeter 200 of the first pocket 110 and includes a first edge 502, a second edge 504, and a third edge 506. As Figure 5 shown, the first surrounding portion 430 extends around or encircles the closed edge of the first pocket 110 (including a first edge 202, a second edge 204, and a third edge 206).

[0056] In some embodiments, the size or area of the first surrounding portion 430 around the closed edge of the first pocket 110 can vary based on the size or area of the first pocket 110. In some cases, the size or area of the first surrounding portion 430 can be a predetermined percentage of the size or area of the first pocket 110. For example, in one embodiment, the size or area of the first surrounding portion 430 can be about 10% of the size or area of the first pocket 110 (e.g., for a pocket with an area of 250 square centimeters, the surrounding portion can be at least 25 square centimeters). In other embodiments, the predetermined percentage can be smaller or larger. For example, in some cases, it can be between 5% - 25% of the size or area of the pocket. Additionally, in some cases, the predetermined percentage can vary based on the stretchability level of the pocket and / or the surrounding portion around the pocket. For example, compared to a surrounding portion formed using a fabric with a non - zero stretchability level, a surrounding portion formed using a fabric that creates a non - stretch zone can be a smaller predetermined percentage of the size or area of the pocket.

[0057] In one embodiment, the single - woven portion forming the first surrounding portion 430 is formed by weaving using a second weave pattern 508. In one embodiment, the second weave pattern 508 can be a reverse twill or herringbone weave pattern or technique. In other embodiments, the second weave pattern 508 can be a plain weave, a fabric type that creates a non - stretch zone, or other types of weaving patterns or techniques. In an exemplary embodiment, the second weave pattern 508 is different from the first weave pattern 500. As described above, in some embodiments, the first surrounding portion 430 having the second weave pattern 508 can be associated with a stretch modulus zone 432 having a stretchability level less than at least one other portion or part of the engineered woven fabric (e.g., a second stretchability level less than the first stretchability level).

[0058] For example, in this embodiment, the first surrounding portion 430 itself is partially surrounded by portions or sections of the first upper portion 414 and / or the first lower portion 416. As Figure 5 shown, the top edge 510 of the first upper portion 414 surrounds at least the first edge 502 of the first surrounding portion 430, the side edges 512 of the first upper portion 414 and / or the first lower portion 416 surround at least the second edge 504 of the first surrounding portion 430, and the bottom edge 514 of the first lower portion 416 surrounds at least the third edge 506 of the first surrounding portion 430.

[0059] In one embodiment, the single-layer woven portion forming the first upper portion 414 and / or the first lower portion 416 is formed by weaving using a third weave pattern 516. In one embodiment, the third weave pattern 516 can be a regular twill weave pattern or technique. In other embodiments, the third weave pattern 516 can be a tear-resistant weave, a weave type including at least one elastic fiber yarn, or other types of weaving patterns or techniques. In an exemplary embodiment, the third weave pattern 516 is different from the second weave pattern 508 and / or the first weave pattern 500. As described above, in some embodiments, the first upper portion 414 and / or the first lower portion 416 having the third weave pattern 516 can be associated with tensile modulus regions 418, 420 having a level of stretchability greater than the tensile modulus region of the first surrounding portion 430 (e.g., a first level of stretchability greater than a second level of stretchability).

[0060] In some embodiments, the stretchability levels of the tensile modulus regions 418, 420 in the first upper portion 414 and / or the first lower portion 416 having the third weave pattern 516 are less than the stretchability level of the first pocket 110. With this arrangement, a gradient of stretchability levels can be formed starting from the region of the article 400 at the opening 114 of the first pocket 110, where the stretchability level can be small or not exhibit stretching characteristics, and the stretchability level can increase as the distance from the opening 114 increases to allow or enable greater stretching. For example, as Figure 4 shown, the tensile modulus region 432 in the first surrounding portion 430 is located closer to the opening 114 and exhibits less stretch than the tensile modulus regions 418, 420 in the first upper portion 414 and / or the first lower portion 416 located farther from the opening 114.

[0061] It should be understood that a substantially similar arrangement may be provided on the second side portion 406 to surround the second pocket 112, where portions or sections of the engineered woven fabric have different tensile modulus zones, as described above with respect to the first pocket 110. With this arrangement, portions of the article 400 having a lesser amount or degree of stretch (e.g., the first circumferential portion 430 and / or the second circumferential portion 434 ( Figure 4 as shown)) can be positioned adjacent to and around the pockets 110, 112, while the remaining portions or sections of the article 400 disposed around the first circumferential portion 430 and / or the second circumferential portion 434 can have a greater amount or degree of stretch, e.g., the first upper portion 414, the first lower portion 416, the second upper portion 422, and / or the second lower portion 424, thereby providing a smoother overall appearance for the article 400 and resisting or preventing bulging or sagging of the pockets 110, 112 when carrying items or objects.

[0062] The principles of this embodiment have been described herein with reference to the front side of the article (e.g., the front side 102 of the article 100 and / or the front side 402 of the article 400). However, these techniques can also be applied to other portions or sections of the article, including but not limited to the back side and / or side panels. For example, the article can include one or more portions or sections on the back side and / or side panels that are woven using a tear-resistant tissue or include elastic fiber yarns to provide varying levels of stretchability in a manner similar to that described with reference to the exemplary embodiments herein. Additionally, the location and / or arrangement of the pockets and the tensile modulus zones can vary based on the type of article or garment.

[0063] In some embodiments, the clothing articles described herein (e.g., the article 100 and / or the article 400) can be woven seamlessly during the same weaving process, including one or more portions or sections having a single-layer weaving construction and one or more portions or sections having a double-layer weaving construction (e.g., the pockets 110, 112). In an exemplary embodiment, after the weaving process for forming the engineered woven fabric is completed, additional steps or processes can be applied to the engineered woven fabric to shape or form it into a specific clothing article, including the article 100 and / or the article 400. In one embodiment, the pockets (e.g., the pockets 110, 112) can be initially formed during the weaving process of the engineered woven fabric, where all edges around the outer perimeter are closed (i.e., joined seamlessly with the surrounding fabric). In such a case, the step of creating or forming an opening in the pockets 110, 112 can be performed when the weaving process is completed to provide access or entry to the cavity in the void space formed between the independent woven layers of the pockets 110, 112.

[0064] Now referring to Figure 6, shows an enlarged representative view of a process 600 for seamlessly forming an opening in a pocket in an engineered woven fabric. In this embodiment, the engineered woven fabric includes a single-layer woven portion 602 that is seamlessly joined to a double-layer woven portion 604. As described above, in some embodiments, a cavity or void space between the individual woven layers of the double-layer woven portion 604 can be formed into a pocket by opening one of the closed edges. In an exemplary embodiment, the double-layer woven portion 604 has an outer perimeter 606 that defines the boundary of a pocket defined by four edges, including a first edge 608, a second edge 610, a third edge 612, and a fourth edge 614).

[0065] In one embodiment, one of the closed edges around the outer perimeter 606 of the double-layer woven portion 604 can be opened to provide an opening and form a pocket. In this embodiment, the process 600 includes using a cutting device 616, such as a knife, blade, or other cutting mechanism, to cut through one or more yarns of the double-layer woven portion 604 along the fourth edge 614. As Figure 6 shown, the cutting device 616 can be moved in a downward direction 618 (e.g., from the first edge 606 toward the third edge 612) to open the double-layer woven portion 604 along the fourth edge 614.

[0066] Figure 7A shows the double-layer woven portion 604 that is seamlessly joined to the single-layer woven portion 602 at both ends, where a cavity or void space 700 is formed between the individual woven layers (including a first woven layer 702 and a second woven layer 704) of the double-layer woven portion 604. As Figure 7B shown, the process 600 is implemented by using the cutting device 616 to cut through the yarns of the first woven layer 702 (e.g., the top layer in this embodiment) of the double-layer woven portion 604 to separate them from the single-layer woven portion 602. As Figure 7C shown, once the yarns of the first woven layer 702 of the double-layer woven portion 604 are cut or separated from the single-layer woven portion 602, the cut portion of the double-layer woven portion 604 becomes a free edge 706 that can be moved away from the second woven layer 704 to provide an opening 708 that allows access to the cavity or void space 700 located between the two individual woven layers 702, 704 of the double-layer woven portion 604. With this arrangement, a pocket can be formed in the engineered woven fabric.

[0067] It should be understood that the process 600 is an example of a method for forming a pocket in an engineered woven fabric. Other techniques can be used, including other mechanisms or techniques for cutting one edge of the double-layer woven portion to form a pocket, as well as integrally forming a free end as part of the double-layer woven portion during the weaving process itself.

[0068] This embodiment has been described with reference to exemplary pockets having a generally rectangular or square shape. In some embodiments, pockets formed in accordance with the techniques described herein may have other shapes, including shapes having fewer or greater numbers of sides or edges. Now referring to Figures 8A to 8C , some additional embodiments of pockets having non-rectangular shapes are shown, which pockets have different numbers of sides or edges. For example, Figure 8A An alternative embodiment of the arrangement of pocket 800 formed in the engineered woven fabric of an article is shown. In this embodiment, pocket 800 includes a first straight edge 802, a curved bottom edge 804, and a second straight edge 806 that may be seamlessly joined to the engineered woven fabric. Pocket 800 also includes a free edge 808 disposed along the top of pocket 800, which free edge 808 provides an opening into pocket 800.

[0069] Figure 8B Another alternative embodiment of the arrangement of pocket 810 formed in the engineered woven fabric of an article is shown. In this embodiment, pocket 810 includes a first straight edge 812, a first angled bottom edge 814, a second angled bottom edge 816, and a second straight edge 818 that may be seamlessly joined to the engineered woven fabric. Pocket 810 also includes a free edge 820 disposed along the top of pocket 810, which free edge 820 provides an opening into pocket 810. Figure 8C is another alternative embodiment of the arrangement of pocket 822 formed in the engineered woven fabric of an article. In this embodiment, pocket 822 includes a first edge 824 and a second edge 826 that may be seamlessly joined to the engineered woven fabric. Pocket 822 also includes a free edge 828 disposed along the top of pocket 822, which free edge 828 provides an opening into pocket 822.

[0070] Additionally, although this embodiment has been described with reference to exemplary embodiments of an article of clothing in the form of a vest (e.g., article 100 and / or article 400), the techniques described herein may be applied to various different types and forms of clothing or apparel. For example, Figures 9A to 9E Different exemplary embodiments of an article of clothing are shown, which include an engineered woven fabric having a pocket formed in accordance with the techniques described herein. Now referring to Figure 9A , an article of clothing 900 in the form of a coat or jacket is shown. In this embodiment, article 900 may include one or more pockets formed in accordance with the techniques described herein, including but not limited to a first side pocket 902, a second side pocket 904, a first chest pocket 906, and a second chest pocket 908.

[0071] Now referring to Figure 9B, shows a clothing article 910 in the form of a shirt or T-shirt. In this embodiment, the article 910 may include one or more pockets formed according to the techniques described herein, including but not limited to a chest pocket 912. In some embodiments, a clothing article wearable on a wearer's leg or lower body may also have pockets formed in an engineered woven fabric as described above. For example, Figure 9C shows a clothing article 920 in the form of pants. In this embodiment, the article 920 may include one or more pockets formed according to the techniques described herein, including but not limited to a first pocket 922 and a second pocket 924. Additionally, in some cases, the article 920 may also include a pocket (not shown) on the dorsal side.

[0072] Now referring to Figure 9D , shows a clothing article 930 in the form of shorts. In this embodiment, the article 930 may include one or more pockets formed according to the techniques described herein, including but not limited to a first pocket 932 and a second pocket 934. Additionally, in some cases, the article 930 may also include a pocket (not shown) on the dorsal side. Now referring to Figure 9E , shows a clothing article 940 in the form of a skirt or dress. In this embodiment, the article 940 may include one or more pockets formed according to the techniques described herein, including but not limited to a first pocket 942 and a second pocket 944.

[0073] Figures 9A to 9E The exemplary embodiments of the clothing articles or garments shown in should not be considered restrictive. Other types or forms of clothing articles or garments may be formed with pockets made according to the exemplary embodiments, which will be apparent to those of ordinary skill in the art in light of this teaching.

[0074] Although various embodiments of the present disclosure have been described, the description is intended to be exemplary, not restrictive, and it will be apparent to those of ordinary skill in the art that there may be more embodiments and implementations within the scope of the present disclosure. Accordingly, the present disclosure is not limited except as by the appended claims and their equivalents. Moreover, various modifications and changes may be made within the scope of the appended claims.

Claims

1. A clothing article comprising an engineered woven fabric, the engineered woven fabric comprising: A single-layer woven portion having at least one warp yarn and at least one weft yarn, the single-layer woven portion being designed to include a first tensile modulus zone having a first level of stretchability and a second tensile modulus zone having a second level of stretchability, the first level of stretchability being greater than the second level of stretchability; And A double-layer woven portion seamlessly joined to the single-layer woven portion, the double-layer woven portion having two independent woven layers, each woven layer having at least one warp yarn and at least one weft yarn, the double-layer woven portion forming a pocket having a closed edge seamlessly joined to the single-layer woven portion and an opening; Wherein the single-layer woven portion is designed such that the second tensile modulus zone is disposed around the closed edge of the pocket to provide support around the pocket.

2. The clothing article according to claim 1, wherein, The second tensile modulus zone is a non-stretch zone.

3. The clothing article according to claim 2, wherein, The second tensile modulus zone is a reverse twill weave.

4. The clothing article according to claim 2, wherein, The second tensile modulus zone is a plain weave.

5. The clothing article according to claim 1, wherein, The first tensile modulus zone includes elastic fiber yarns.

6. The clothing article according to claim 5, wherein, The elastic fiber yarns are added in the warp direction and / or the weft direction of the first tensile modulus zone.

7. The clothing article according to claim 1, wherein, The first tensile modulus zone is a tear-resistant weave.

8. The clothing article according to claim 1, wherein, The single-layer woven portion includes at least one additional tensile modulus zone having a stretchability level different from the first and second levels of stretchability.

9. The clothing article according to claim 1, wherein, The single-layer woven portion includes two or more warp yarns and two or more weft yarns.

10. The clothing article according to claim 1, wherein, The double-layer woven portion is designed to include a third tensile modulus zone having a third level of stretchability and a fourth tensile modulus zone having a fourth level of stretchability, the third level of stretchability being greater than the fourth level of stretchability.

11. The clothing article according to claim 10, wherein, The fourth tensile modulus zone is a non-tensile modulus zone.

12. The clothing article according to claim 10, wherein, The third tensile modulus zone includes elastic fiber yarns.

13. The clothing article according to claim 12, wherein, The elastic fiber yarns are added in the warp direction and / or the weft direction of the third tensile modulus zone.

14. The clothing article according to claim 1, further comprising a gradient of the stretchability level of the single-layer woven portion, the gradient of the stretchability level increasing the stretchability as the distance from the opening of the pocket increases.

15. The clothing article according to claim 14, wherein, The second tensile modulus zone is a non-stretch zone disposed adjacent to the opening of the pocket; Wherein the first tensile modulus zone is located at a distance away from the opening of the pocket; and Wherein the gradient of the stretchability level increases from the second level of stretchability in the second tensile modulus zone to the first level of stretchability in the first tensile modulus zone.

16. The clothing article according to claim 1, wherein, The double-layer woven portion includes two or more warp yarns and two or more weft yarns.

17. The clothing article according to claim 1, wherein, The article is a jacket, vest, shirt, pants, shorts, dress or skirt.

18. The clothing article according to claim 1, wherein, The stretchability level of one of the two independent woven layers forming the double-layer woven portion is greater than the stretchability level of the other woven layer.

19. A clothing article comprising an engineered woven fabric, the engineered woven fabric comprising: A pocket formed in the engineered woven fabric, the pocket including a plurality of closed edges and a free edge, the plurality of closed edges being disposed around an outer periphery of the pocket, the free edge providing an opening into a cavity of the pocket; A surrounding portion of the engineered woven fabric, the surrounding portion surrounding at least two of the plurality of closed edges around the outer periphery of the pocket; And At least one additional portion of the engineered woven fabric, the additional portion surrounding the surrounding portion; Wherein the at least one additional portion of the engineered woven fabric includes a first tensile modulus zone having a first level of stretchability; Wherein the surrounding portion includes a second tensile modulus zone having a second level of stretchability, the second level of stretchability being less than the first level of stretchability to provide support around the pocket.

20. The clothing article according to claim 19, wherein, The surrounding portion includes a single-layer woven portion having at least one warp yarn and at least one weft yarn; and wherein the pocket includes a double-layer woven portion having two independent woven layers, each independent woven layer having at least one warp yarn and at least one weft yarn, the double-layer woven portion of the pocket being seamlessly joined to the single-layer woven portion of the surrounding portion along each of the closed edges.

21. The clothing article according to claim 20, wherein, One of the two independent woven layers is separated from the other woven layer to form the free edge.

22. The clothing article according to claim 20, wherein, One of the two independent woven layers has a greater level of stretchability than the other woven layer.

23. The clothing article according to claim 22, wherein, One of the two independent woven layers having the greater level of stretchability includes one quarter of the total number of yarns forming the engineered woven fabric, and the other woven layer includes three quarters of the total number of yarns forming the engineered woven fabric.

24. The clothing article according to claim 19, wherein, The first tensile modulus zone is associated with a first weave pattern, and the second tensile modulus zone is associated with a second weave pattern, the second weave pattern being different from the first weave pattern.

25. The clothing article according to claim 19, wherein, The engineered woven fabric has a gradient of levels of stretchability, the gradient of levels of stretchability increasing in stretchability with an increase in distance from the opening of the pocket.

26. A method of forming a clothing article, the clothing article including an engineered woven fabric having a seamless pocket, the method including: Weaving an engineered woven fabric, the engineered woven fabric including: (1) a single-layer woven portion having at least one warp yarn and at least one weft yarn; and (2) a double-layer woven portion having two independent woven layers, each woven layer having at least one warp yarn and at least one weft yarn, wherein the double-layer woven portion is seamlessly joined to the single-layer woven portion during the weaving process; Wherein weaving the single-layer woven portion further includes: Weaving a first tensile modulus zone having a first level of stretchability in a first portion of the engineered woven fabric; and Weaving a second tensile modulus zone having a second level of stretchability in a second portion of the engineered woven fabric, the first level of stretchability being greater than the second level of stretchability; Wherein, weaving the double-layer weaving part further includes forming a pocket in the engineered woven fabric, wherein a closing edge extends around the outer periphery of the pocket, and the closing edge is seamlessly joined to the single-layer weaving part; and Cutting one of the two independent woven layers along one edge of the closing edge extending around the outer periphery of the pocket to separate the one woven layer and form a free edge, wherein the free edge provides an opening into a cavity formed between the two independent woven layers of the pocket.

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