Woven fabric with thermal insulation zone and pile zone

Abstract

Embodiments of the present disclosure relate to a fabric having one or more insulation zones and one or more pile zones, and a garment produced from the fabric, where the pile zone extends seamlessly from the insulation zone. The fabric includes a first woven fabric layer, a second woven fabric layer, and a nonwoven fabric layer positioned between the first and second woven fabric layers. In the insulation zone, the first woven fabric layer, the second woven fabric layer, and the nonwoven fabric layer are not attached to each other. In the pile zone, fibers / filaments from the nonwoven fabric layer are entangled with fibers, filaments, and yarns from the first and second woven fabric layers, respectively.

Description

[Technical Field]

[0001] SUMMARY OF THE INVENTION Aspects of the present disclosure relate to fabrics and to garments formed from fabrics having insulating zones and pile zones formed from a combination of woven and nonwoven layers. [Background technology]

[0002] For example, conventional garments including insulation zones and pile zones are generally formed using a panel-type cut-and-sew construction, where seams are used to attach the fabric forming the insulation zone to the fabric forming the pile zone. The seam lines can introduce areas of structural weakness, can be aesthetically unpleasing, and / or can cause chafing or discomfort to the wearer. Summary of the Invention

[0003] The following clauses provide exemplary aspects of the concepts contemplated herein. Any one of the following clauses may be combined in a multiple dependent manner and depend on one or more other clauses. Furthermore, any combination of dependent clauses (clauses that are explicitly dependent on a previous clause) may be combined while remaining within the scope of the aspects contemplated herein. The following clauses are examples and not limiting.

[0004] Clause 1. A fabric comprising: an insulation zone comprising a first woven fabric layer, a second woven fabric layer, and a nonwoven fabric layer positioned between the first and second woven fabric layers, wherein each of the first and second woven fabric layers is not attached to the nonwoven fabric layer within the insulation zone; and a pile zone extending seamlessly from the insulation zone, the pile zone comprising the first woven fabric layer, the second woven fabric layer, and the nonwoven fabric layer positioned between the first and second woven fabric layers; wherein fibers and / or filaments from the nonwoven fabric layer are entangled with fibers, filaments, and / or yarns from the first and second woven fabric layers, respectively, such that the first and second woven fabric layers are bound to the nonwoven fabric layer within the pile zone.

[0005] Clause 2. The fabric of clause 1, wherein the nonwoven layer comprises two or more nonwoven sheets, and the fibers and / or filaments from each of the two or more nonwoven sheets are entangled with one another.

[0006] Clause 3. The fabric of clause 2, wherein a first nonwoven sheet of the two or more nonwoven sheets has a first visual characteristic and a second nonwoven sheet of the two or more nonwoven sheets has a second visual characteristic that is different from the first visual characteristic.

[0007] Clause 4. The woven fabric of clause 3, wherein the first visual characteristic comprises a first color and the second visual characteristic comprises a second color.

[0008] Clause 5. The woven fabric of clause 3 or 4, wherein the first visual characteristic comprises a first pattern and the second visual characteristic comprises a second pattern.

[0009] Clause 6. The fabric of any one of clauses 1-5, wherein the nonwoven layer has a weight of from about 180 grams per square meter (gsm) to about 220 gsm.

[0010] Clause 7. A garment comprising: an insulation zone comprising a first woven fabric layer, a second woven fabric layer, and a nonwoven fabric layer positioned between the first and second woven fabric layers, wherein the first woven fabric layer, the second woven fabric layer, and the nonwoven fabric layer comprise separate and distinct layers within the insulation zone; and a pile zone extending seamlessly from the insulation zone, wherein the pile zone comprises the first woven fabric layer, the second woven fabric layer, and the nonwoven fabric layer; wherein fibers and / or filaments from the nonwoven fabric layer are entangled with fibers, filaments, and / or yarns from the first and second woven fabric layers, respectively, within the pile zone, such that the first and second woven fabric layers are bound to the nonwoven fabric layer within the pile zone.

[0011] Clause 8. The garment of clause 7, wherein both the first woven layer and the second woven layer are not attached to the nonwoven layer in the insulating zone.

[0012] Clause 9. The garment of clause 7 or 8, wherein the nonwoven layer has visual properties that differ from the visual properties of one or more of the first woven layer and the second woven layer.

[0013] Clause 10. The garment of any one of clauses 7-9, wherein the nonwoven layer comprises two or more nonwoven sheets, and the fibers and / or filaments from each of the two or more nonwoven sheets are entangled with one another.

[0014] Clause 11. The garment of clause 10, wherein a first nonwoven sheet of the two or more nonwoven sheets has a first visual characteristic and a second nonwoven sheet of the two or more nonwoven sheets has a second visual characteristic that is different from the first visual characteristic.

[0015] Clause 12. The garment of any one of clauses 7-11, wherein the nonwoven layer has a weight of about 180 grams per square meter (gsm) to about 220 gsm.

[0016] Clause 13. A garment according to any one of clauses 7 to 12, wherein when the garment is in a worn configuration, the insulating zones are positioned in areas on the garment that correspond to areas of high heat loss on the wearer.

[0017] Clause 14. A method for manufacturing a woven fabric, comprising the steps of positioning a nonwoven layer between a first woven layer and a second woven layer to form a layered configuration, and entangling fibers and / or filaments from the nonwoven layer with fibers, filaments, and / or yarns from each of the first and second woven layers in a first region of the layered configuration, wherein each of the first and second woven layers remains unattached to the nonwoven layer in a second region of the layered configuration.

[0018] Clause 15. The method of producing a woven fabric according to clause 14, wherein the nonwoven layer is formed by positioning two or more nonwoven sheets adjacent to one another and entangling the fibers and / or filaments from each of the two or more nonwoven sheets with one another using an entanglement process.

[0019] Clause 16. The method for producing a woven fabric according to clause 15, wherein the entangling step is carried out in a direction from the first surface of the nonwoven layer to the second surface of the nonwoven layer and in a direction from the second surface of the nonwoven layer to the first surface of the nonwoven layer.

[0020] Clause 17. A method for producing a woven fabric according to any one of clauses 14 to 16, wherein the step of entangling the fibers and / or filaments from the nonwoven fabric layer with the fibers, filaments, and / or yarns from the respective first and second woven fabric layers comprises: positioning the first woven fabric layer adjacent to a first surface of the nonwoven fabric layer and performing a first entangling step in a direction from the nonwoven fabric layer towards the first woven fabric layer; and then positioning the second woven fabric layer adjacent to a second, opposite surface of the nonwoven fabric layer and performing a second entangling step in a direction from the first woven fabric layer towards the second woven fabric layer.

[0021] Clause 18. The method of any one of clauses 14 to 17, wherein the nonwoven layer has a weight of from about 180 grams per square meter (gsm) to about 220 gsm.

[0022] Clause 19. A method for producing a woven fabric according to any one of clauses 14 to 18, wherein the nonwoven layer has visual properties that differ from the visual properties of one or more of the first woven layer and the second woven layer.

[0023] Clause 20. The method of manufacturing a woven fabric according to clause 19, wherein the visual characteristic of one or more of the nonwoven layer and the first and second woven layers comprises color. [Brief explanation of the drawings]

[0024] Examples of aspects of the present specification are described in detail below with reference to the accompanying drawings. [Figure 1] 1 illustrates a view of a first surface of an exemplary fabric having an insulating zone and a pile zone according to an embodiment of the present disclosure. [Figure 2] 2 illustrates a view of a second opposing surface of the exemplary fabric of FIG. 1 showing an insulating zone and a pile zone according to an embodiment herein. [Figure 3]2 illustrates a cross-sectional view of the exemplary fabric of FIG. 1 according to an embodiment of the present disclosure. [Figure 4] 2 illustrates a schematic diagram of an exemplary process for forming a nonwoven layer of the exemplary fabric of FIG. 1 according to embodiments herein. [Figure 5] 2 illustrates a schematic diagram of an exemplary process for forming the exemplary fabric of FIG. 1 according to an embodiment of the present disclosure. [Figure 6] 2 illustrates an exemplary upper body garment incorporating the exemplary fabric of FIG. 1 according to embodiments herein. [Figure 7] 2 illustrates an exemplary lower body garment incorporating the exemplary fabric of FIG. 1 according to embodiments herein. [Figure 8] 2 illustrates a flow diagram of an exemplary method for producing the fabric of FIG. 1 according to embodiments herein. DETAILED DESCRIPTION OF THE INVENTION

[0025] The subject matter of the present invention is described with specificity herein to satisfy statutory requirements. However, the description itself is not intended to limit the scope of the present disclosure. Rather, the inventors contemplate that the claimed or disclosed subject matter may also be embodied in other ways and may include different steps or combinations of steps similar to those described in this document, in conjunction with other current or future technologies. Furthermore, although the terms "step" and / or "block" may be used herein to connote different elements of the method employed, the terms should not be construed to imply any particular order between the various steps disclosed in the present invention unless and until the order of individual steps is explicitly recited.

[0026] Conventional garments having an insulating zone and a pile zone (i.e., a fleece-like zone) are generally formed using a panel-type cut-and-sew construction, in which the fabric used to form the insulating zone is seamed to the fabric used to form the pile zone. The resulting seams can introduce structurally weak areas, create undesirable aesthetics, and / or cause chafing or discomfort to the wearer. Furthermore, the fabrics used to form conventional pile zones can lack characteristics that make them suitable for use in adverse weather conditions such as rain, snow, and / or wind.

[0027] Embodiments of the present specification relate to fabrics, garments formed from the fabrics, and methods for manufacturing the fabrics, wherein the fabrics have an insulating zone and a pile zone that extend seamlessly from one another. Furthermore, due to the configuration of the pile zone, the pile zone includes characteristics that make it more resistant to adverse weather conditions than typical pile fabrics. In an exemplary embodiment, the insulating zone includes a first woven fabric layer, a second woven fabric layer, and a nonwoven fabric layer positioned in the space between the first and second woven fabric layers. In the insulating zone, the first woven fabric layer, the second woven fabric layer, and the nonwoven fabric layer are not attached to one another, so that the first woven fabric layer, the second woven fabric layer, and the nonwoven fabric layer are separate and distinct layers. In addition to the spaces formed between different layers that can be used to trap heated air, the nonwoven fabric layer includes numerous spaces between the fibers and filaments that form the nonwoven fabric layer, which further help trap heated air and insulate the wearer.

[0028] The pile zone includes a first woven fabric layer, a second woven fabric layer, and a nonwoven fabric layer. In the pile zone, fibers / filaments from the nonwoven fabric layer extend into and through the first and second woven fabric layers and become entangled with fibers, filaments, and / or yarns from both the first and second woven fabric layers, for example, through an entanglement process (e.g., needlepunching, etc.). Because the nonwoven fibers / filaments are entangled with the first and second woven fabric layers, the first and second woven fabric layers are bound or fixed to the nonwoven fabric layers in the pile zone. The pile zone has a fleece-like texture due to the fibers / filaments from the nonwoven fabric layers extending through the first and second woven fabric layers. Unlike typical pile fabrics, in which tufts or loops extend integrally from a base fabric, which may not exhibit weather-resistant properties, the pile zone contemplated herein may have weather-resistant properties due to the presence of the first and second woven fabric layers. For example, in exemplary embodiments in which the first and second woven fabric layers are tightly woven, the pile zone may exhibit wind-resistant properties. In additional exemplary embodiments in which one or more of the first and second woven fabric layers are treated with a durable water repellent, the pile zone may generally be resistant to rain or precipitation.

[0029] While the insulation zone and pile zone are formed from the same material, embodiments herein contemplate variations in aesthetics between the insulation zone and the pile zone, for example, based on the entanglement process. For example, the first woven fabric layer and / or the second woven fabric layer may have a first visual characteristic. The nonwoven fabric layer may have a second visual characteristic that is different from the first visual characteristic. In this embodiment, because the nonwoven fabric layer is positioned between the first woven fabric layer and the second woven fabric layer and may not be visible, the insulation zone may primarily exhibit or display the first visual characteristic associated with the first woven fabric layer and / or the second woven fabric layer. Due to the entanglement of the fibers, filaments, and yarns of the first woven fabric layer and / or the second woven fabric layer with the fibers and filaments of the nonwoven fabric layer, the pile zone may exhibit or display a different visual characteristic that is intermediate between the first visual characteristic and the second visual characteristic. By way of example, the first woven fabric layer and / or the second woven fabric layer may be white, and the nonwoven fabric layer may be gray. The insulating zone may exhibit or appear primarily white in color, and the pile zone may have a heather grey and white appearance due to the mixture of white yarns forming the first and / or second woven layers and grey fibres / filaments forming the nonwoven layers.

[0030] As used herein, the term "garment" encompasses any number of products intended to be worn by a wearer, including upper-body garments (e.g., shirts, jackets, hoodies, tank tops, pullovers), lower-body garments (e.g., pants, shorts, leggings), footwear such as shoes or socks, headwear (e.g., hats), gloves, sleeves (e.g., arm sleeves, calf sleeves), and the like. Positional terms used in describing garments, such as front, back, inward-facing surface, outward-facing surface, and the like, refer to the garment as it would be worn by a wearer in an upright position. Thus, when the garment is in the form of an upper-body garment, the front of the upper-body garment is configured to cover, for example, the upper front torso region and the front arm regions (if the garment has sleeves), and the back of the upper-body garment is configured to cover the upper back torso region and the back arm regions (if the garment has sleeves). When the garment is in the form of a lower-body garment, the front of the lower-body garment is configured to cover, for example, the wearer's lower front torso region and the front leg region, and the back of the lower-body garment is configured to cover the wearer's lower back torso region and the back leg region. Similarly, the inner surface of the garment is configured to face inward (e.g., face the wearer's body surface), and the outer surface of the garment is configured to face the external environment or with the inner surface of the garment facing away from the wearer. It is contemplated herein that in some embodiments, the inner surface of the garment may comprise the innermost surface of the garment. In some embodiments, the outer surface of the garment may comprise the outermost surface of the garment.

[0031] As used herein, the term "yarn" may refer to a collection of fibers or filaments twisted or grouped together to form a continuous strand. The term "yarn" may also encompass a single monofilament that forms a continuous strand. In exemplary embodiments, the first and second woven fabric layers described herein may be formed from yarns and the fibers or filaments that form the yarns. The nonwoven fabric layers described herein may be formed from fibers and / or filaments.

[0032] The term "woven layer" refers to a fabric having multiple warp yarns and multiple weft yarns interwoven with the multiple warp yarns, where the multiple weft yarns generally extend perpendicular to the multiple warp yarns. As used herein, the term "nonwoven layer" refers to fibers or filaments that are held together by mechanical and / or chemical interactions, rather than in the form of a knitted, woven, braided, or other structured configuration. In certain embodiments, nonwoven fabrics comprise a collection of fibers or filaments that are mechanically manipulated to form a mat-like material. In other words, nonwoven fabrics are made directly from fibers or filaments. As used herein, the term "pile" or "pile zone" refers to a fabric, including a composite fabric, having a raised surface formed from upstanding loops or strands of fibers / filaments.

[0033] The term "extending seamlessly" refers to two regions or zones that extend seamlessly into one another. For purposes of this disclosure, the insulation zone and the pile zone extend seamlessly into one another such that one or more warp and / or weft yarns in the insulation zone extend continuously and uninterrupted into the pile zone.

[0034] As used herein, "visual characteristics" broadly refers to the visual impression produced by a fabric. This may be due to different characteristics of the yarns / fibers / filaments used to form the fabric, including differences in texture, denier, luster, color, and the like. With respect to the term "pattern," the term generally refers to a repeated decorative design. With respect to the term "color," the term generally relates to the color of the fabric, which may be imparted by dyes and / or colorants. Furthermore, for example, when describing a fabric, the term "color" refers to the observable color of the yarns / fibers / filaments that form the fabric. In such embodiments, it is contemplated that the color may be any color imparted to the yarns / fibers / filaments using dyes, pigments, and / or colorants known to those skilled in the art. Thus, the yarns / fibers / filaments may be configured to have colors including, but not limited to, red, orange, yellow, green, blue, indigo, purple, white, black, and shades thereof.

[0035] Embodiments relating to color further contemplate determining whether one color differs from another. In such embodiments, color may have a color number, which may be determined using an instrument that objectively measures and / or calculates the color value of an object's color by normalizing and / or quantifying factors that may affect color perception. Such instruments include, but are not limited to, spectroradiometers, spectrophotometers, and the like. Accordingly, embodiments herein contemplate that the "color" of a fabric provided by a yarn / fiber / filament may have a color number, which is determined by measuring and / or calculating using a spectroradiometer and / or spectrophotometer. Furthermore, color numbers may be associated with a color space or color model, which is a particular organization of colors that provides a color representation of the color number; thus, each color number corresponds to a single color represented in the color space or color model.

[0036] In such embodiments, a color can be determined to be different from another color if the color numerical values ​​of each color are different. Such a determination can be made, for example, by measuring and / or calculating the color numerical value of a first fabric having a first color using a spectroradiometer or spectrophotometer, measuring and / or calculating the color numerical value of a second fabric having a second color using the same instrument (i.e., if a spectrophotometer is used to measure the color numerical value of the first color, a spectrophotometer is used to measure the color numerical value of the second color), and comparing the color numerical value of the first color to the color numerical value of the second color. In another example, the determination can be made by measuring and / or calculating the color numerical value of a first region of the fabric using a spectroradiometer or spectrophotometer, measuring and / or calculating the color numerical value of a second region of the fabric having the second color using the same instrument, and comparing the color numerical value of the first color to the color numerical value of the second color. If the color numerical values ​​are not equal, the first color is different from the second color, and vice versa.

[0037] Furthermore, the visual distinction between two colors may be correlated to the percentage difference between the color values ​​of the first and second colors, with the visual distinction considered to increase as the percentage difference between the color values ​​increases. Furthermore, the visual distinction may be based on a comparison between color representations of color values ​​in a color space or model. For example, if a first color has a color value corresponding to a black or navy blue display color and a second color has a color value corresponding to a red or yellow display color, the visual distinction between the first and second colors is greater than the visual distinction between a first color having a red display color and a second color having a yellow display color.

[0038] Unless otherwise stated, all measurements provided herein are taken at standard ambient temperature and pressure (25° C. or 298.15 K, 1 bar).

[0039] 1 and 2 show diagrams of a first surface 101 and a second opposing surface 201 of an exemplary fabric 100, respectively. The fabric 100 includes an insulating zone 110 and a pile zone 112. With reference to FIG. 1 , the first surface 101 of the insulating zone 110 is formed from a first woven fabric layer 114. In exemplary embodiments, the first woven fabric layer 114 may include nylon yarns, polyester yarns, combinations of nylon and polyester yarns, and the like. When the fabric 100 is incorporated into a garment, the first woven fabric layer 114 of the insulating zone 110 may form the outermost surface of the garment. In exemplary embodiments, the first woven fabric layer 114 may be tightly woven, such that the first woven fabric layer 114 is generally resistant to wind penetration and / or rain penetration. Having a tightly woven first woven fabric layer 114 also helps maintain heated air in the space between the first woven fabric layer 114 and the second woven fabric layer. In further exemplary embodiments, the first woven fabric layer 114 may be treated with a durable water repellent finish to improve the water resistance or water repellency of the first woven fabric layer 114. The first woven fabric layer 114 may have visual characteristics such as a color or pattern.

[0040] The first surface 101 of the pile zone 112 is formed from a first woven fabric layer 114 and fibers / filaments 116 of a nonwoven fabric layer positioned between the first woven fabric layer 114 and a second woven fabric layer, as discussed below. The fibers / filaments 116 of the nonwoven fabric layer extend through the first surface 101 within the pile zone 112, such that the fibers / filaments 116 of the nonwoven fabric layer extend outward (i.e., in the positive Z direction) from the surface plane of the first woven fabric layer 114. This configuration imparts a fleece-like texture to the pile zone 112. Due to the presence of the first woven fabric layer 114, the pile zone 112 may also exhibit weather-resistant properties while providing a pleasant hand and fleece-like aesthetic.

[0041] With reference to FIG. 2 , the second surface 201 of the insulation zone 110 is formed from a second woven fabric layer 214. In an exemplary embodiment, the second woven fabric layer 214 may include nylon yarn, polyester yarn, a combination of nylon and polyester yarn, and the like. When the fabric 100 is incorporated into a garment, the second woven fabric layer 214 of the insulation zone 110 may form the innermost surface of the garment. Like the first woven fabric layer 114, the second woven fabric layer 214 may be tightly woven, so that heated air trapped in the space between the first and second woven fabric layers 114 is generally retained in the space to help warm and insulate the wearer. The second woven fabric layer 214 may also have visual characteristics, such as a color or pattern. The visual characteristics of the second woven fabric layer 214 may be the same as or different from the visual characteristics of the first woven fabric layer 114.

[0042] The second surface 201 of the pile zone 112 is formed from the second woven fabric layer 214 and the fibers / filaments 116 of the nonwoven fabric layer positioned between the first woven fabric layer 114 and the second woven fabric layer 214. The fibers / filaments 116 of the nonwoven fabric layer extend through the second surface 201 in the pile zone 112 such that the fibers / filaments 116 of the nonwoven fabric layer extend outward from the surface plane of the second woven fabric layer 214 (i.e., in the negative Z direction relative to the fibers / filaments 116 extending through the first surface 101), imparting a fleece-like texture to the second surface 201 of the pile zone 112. As shown, the location of the pile zone 112 on the first surface 101 of the fabric 100 corresponds to the location of the pile zone 112 on the second surface 201 of the fabric 100. Similarly, the location of the insulating zone 110 on the first surface 101 of the fabric 100 corresponds to the location of the insulating zone 110 on the second surface 201 of the fabric 100. In other words, the insulating zone 110 and the pile zone 112 are symmetrically located on the opposing surfaces 101 and 201 of the fabric 100.

[0043] 3 shows a cross-section of the fabric 100 through the insulation zone 110 and the pile zone 112. As shown, the insulation zone 110 includes a first woven fabric layer 114 and a second woven fabric layer 214. The first woven fabric layer 114 includes a first surface 113 and a second surface 115 opposite the first surface 113. In the exemplary embodiment, the first surface 113 of the first woven fabric layer 114 forms the first surface 101 of the insulation zone 110 of the fabric 100. The second woven fabric layer 214 also includes a first surface 213 and a second surface 215 opposite the first surface 213. In the exemplary embodiment, the first surface 213 of the second woven fabric layer 214 forms the second surface 201 of the insulation zone 110 of the fabric 100.

[0044] A nonwoven layer 310 having a first surface 312 and a second surface 314 opposite the first surface 312 is positioned in the space formed between the first woven layer 114 and the second woven layer 214. More specifically, the first surface 312 of the nonwoven layer 310 is positioned adjacent to the second surface 115 of the first woven layer 114, and the second surface 314 of the nonwoven layer 310 is positioned adjacent to the second surface 215 of the second woven layer 214. As described in more detail below, the nonwoven layer 310 may include two or more nonwoven sheets intertwined with one another. In an exemplary embodiment, the fibers / filaments 116 of the nonwoven layer 310 may be formed from polyester fibers / filaments, including recycled polyester fibers / filaments, although other materials, including natural materials, are contemplated herein. In exemplary embodiments, nonwoven layer 310 has a weight of about 150 grams per square meter (gsm) to about 250 gsm, about 170 gsm to about 230 gsm, about 190 gsm to about 210 gsm, or about 200 gsm. As used herein, the term "about" means within ±10% of the stated value. The weight of nonwoven layer 310 can be measured, for example, using ISO 3801 testing standards.

[0045] In the insulation zone 110, the first woven fabric layer 114, the nonwoven fabric layer 310, and the second woven fabric layer 214 are separated and distinct from one another, such that a space, or potential space, is maintained between the second surface 115 of the first woven fabric layer 114 and the first surface 312 of the nonwoven fabric layer 310, and between the second surface 215 of the second woven fabric layer 214 and the second surface 314 of the nonwoven fabric layer 310. In other words, in the insulation zone 110, the first woven fabric layer 114, the nonwoven fabric layer 310, and the second woven fabric layer 214 are not attached or stuck to one another. In the insulation zone 110, the space between the first woven fabric layer 114, the second woven fabric layer 214, and the nonwoven fabric layer 310 serves to trap heated air and insulate a wearer of a garment incorporating the fabric 100. Additionally, the spaces between the fibers / filaments 116 that form the nonwoven layer 310 also help to trap heated air, further increasing the insulating characteristics of the insulating zone 110 .

[0046] The pile zone 112 of the fabric 100 extends seamlessly from the insulation zone 110, as shown in FIG. 3 . In other words, one or more warp or weft yarns in the insulation zone 110 extend continuously and uninterrupted into the pile zone 112. The pile zone 112 is created by an entanglement process, whereby the fibers / filaments 116 of the nonwoven layer 310 become entangled with the fibers, filaments, and / or yarns of the first woven layer 114 and the second woven layer 214. In exemplary embodiments, the integrity of the first woven layer 114 and the second woven layer 214 generally remains intact within the pile zone 112. For example, the warp and weft yarns forming the first woven layer 114 and the second woven layer 214 generally remain interwoven within the pile zone 112.

[0047] 3 , the fibers / filaments 116 of the nonwoven layer 310 extend into the first woven layer 114. In some exemplary embodiments, the fibers / filaments 116 of the nonwoven layer 310 extend through the first woven layer 114 (i.e., extend through the first surface 113 of the first woven layer 114), such that the fibers / filaments 116 of the nonwoven layer 310 extend outward from the first surface 101 of the fabric 100 within the pile zone 112. Similarly, the fibers / filaments 116 of the nonwoven layer 310 extend into the second woven layer 214. In some exemplary embodiments, the fibers / filaments 116 of the nonwoven layer 310 extend through the second woven layer 214 (i.e., extend through the first surface 213 of the second woven layer 214), such that the fibers / filaments 116 of the nonwoven layer 310 extend outward from the second surface 201 of the fabric 100 in the pile zone 112. Because the fibers / filaments 116 of the nonwoven layer 310 are entangled with the first woven layer 114 and the second woven layer 214 in the pile zone 112, the first woven layer 114 and the second woven layer 214 are constrained or secured to the nonwoven layer 310 in the pile zone 112. The fibers / filaments 116 of the nonwoven layer 310 extend through the first woven layer 114 and the second woven layer 214, thereby creating a pile or fleece-like texture on the first surface 101 and the second surface 201 of the fabric 100 in the pile zone 112. Consequently, this provides excellent hand and pleasing aesthetics. Furthermore, because the first woven layer 114 and the second woven layer 214 are present in the pile zone 112, the pile zone 112 also exhibits wind- and / or rain-resistant properties due to the tightly woven nature of the first woven layer 114 and / or the second woven layer 214.

[0048] FIG. 4 illustrates a schematic diagram of an exemplary process 400 for forming a nonwoven layer 310. In step 410, two or more nonwoven sheets are provided. Each of the two or more nonwoven sheets may be formed of a web of fibers that undergoes carding and wrapping processes to align the fibers in one or more common directions extending generally along the x,y plane and achieve a desired basis weight. The web of fibers may also undergo a light needling or mechanical entanglement process, which entangles the web of fibers to the extent that the web forms a cohesive structure that can be manipulated (e.g., wound on a roller, unrolled from a roller, or stacked). The nonwoven sheets may also undergo one or more additional processing steps, such as printing (digital printing, dye sublimation printing, inkjet printing, and the like). In an exemplary embodiment, four nonwoven sheets 412, 414, 416, and 418 are provided. Each of the four nonwoven sheets 412, 414, 416, and 418 may have a basis weight of about 35 gsm to about 65 gsm, about 40 gsm to about 60 gsm, about 45 gsm to about 55 gsm, or about 50 gsm to achieve a desired basis weight of about 150 gsm to about 250 gsm for the nonwoven layer 310. The nonwoven sheets 412, 414, 416, and 418 may each have visual characteristics 420, 422, 424, and 426, which are indicated by different shading patterns. The visual characteristics 420, 422, 424, and 426 may be imparted through a printing process (digital printing, dye sublimation printing, inkjet printing, and the like). Additionally or alternatively, visual characteristics 420, 422, 424, and 426 may be imparted using dyed fibers / filaments that form nonwoven sheets 412, 414, 416, and 418. Although visual characteristics 420, 422, 424, and 426 are shown as different, two or more of the visual characteristics are considered to be the same herein. Visual characteristics 420, 422, 424, and 426 may include color, pattern, combination of color and pattern, and the like.

[0049] In step 428, nonwoven sheets 412, 414, 416, and 418 are positioned on top of each other or laminated to form a layered configuration. Depending on the desired visual characteristics of nonwoven layer 310, nonwoven sheets 412, 414, 416, and 418 may be arranged in a specific order, although random arrangement is also contemplated. In step 430, a first entangling step 432 is performed from a first side or surface of the layered configuration through a second side or surface of the layered configuration. Additionally, a second entangling step 434 is performed from a second side or surface of the layered configuration through the first side or surface of the layered configuration. The first and second entangling steps 432 and 434 may comprise mechanical processes such as needlepunching or hydroentangling, although other entangling processes are also contemplated herein. The first and second entangling steps 432 and 434 entangle the fibers / filaments from the nonwoven sheets 412, 414, 416, and 418, respectively, thereby attaching the nonwoven sheets 412, 414, 416, and 418 to one another into a coherent single layer structure. In exemplary embodiments, the first and second entangling steps 432 and 434 may each be performed several times (e.g., from two to seven times) to achieve the desired integrity or cohesion of the nonwoven layer 310. In one exemplary embodiment, the first and second entangling steps 432 and 434 may each be performed five times to achieve the desired cohesion while having the desired loft of the nonwoven layer 310.

[0050] Step 436 shows nonwoven layer 310 being formed by entanglement of the fibers / filaments of nonwoven sheets 412, 414, 416, and 418. Nonwoven layer 310 is shown as a continuous sheet without holes or openings. It is contemplated herein that nonwoven layer 310 may include holes or openings. The holes or openings may be formed during the entanglement process or in a post-processing step using, for example, die cutting, laser cutting, water jet cutting, and the like.

[0051] Because the fibers / filaments from each of the nonwoven sheets 412, 414, 416, and 418 are entangled with one another, the visual characteristics of the nonwoven layer 310 represent a composite or blend of the respective visual characteristics 420, 422, 424, and 426, as indicated by the shading pattern of step 436. In an exemplary embodiment, the amount of entanglement between the different nonwoven sheets 412, 414, 416, and 418 affects the visual characteristics of the resulting nonwoven layer 310. Using the illustrated example, the visual characteristics 420 and 424 may comprise a blue color, and the visual characteristics 422 and 426 may comprise a yellow color. If more first and second entanglement steps 432 and 434 are performed, the visual characteristics of the nonwoven layer 310 may generally comprise a green color due to the increased entanglement of blue and yellow fibers and filaments. If the first and second entangling steps 432 and 434 are performed less, the visual characteristics of the nonwoven layer 310 may have a heather color with blue areas mixed with yellow areas.

[0052] In one exemplary embodiment, one of the nonwoven sheets, such as nonwoven sheet 412 or nonwoven sheet 418, or an additional nonwoven sheet not shown, can be added after the first and second entangling steps 432 and 434 have been performed one or more times. By introducing a nonwoven sheet later in the entangling steps, visual features present in the introduced nonwoven sheet may be more pronounced or less intermixed within the resulting nonwoven layer 310. In the illustrated example, nonwoven sheet 412 can be introduced after the first and second entangling steps 432 and 434 have been performed, for example, three times. In this example, visual feature 420 can comprise a pattern such as diagonal stripes. The first and second entangling steps 432 and 434 can be performed, for example, two more times to produce nonwoven layer 310. Because nonwoven sheet 412 is less entangled than the remaining nonwoven sheets 414 , 416 , and 418 , visual feature 420 stands out from visual features 422 , 424 , and 426 in the resulting nonwoven layer 310 .

[0053] 5 shows a schematic diagram of an exemplary process 500 for forming the fabric 100. In step 510, a first woven fabric layer 114 and a nonwoven fabric layer 310 are provided. The first woven fabric layer 114 includes a visual characteristic 512, and the nonwoven fabric layer 310 includes a visual characteristic 514, as indicated by the shading pattern. In an exemplary embodiment, the visual characteristic 512 may be the same as or different from the visual characteristic 514. The visual characteristics 512 and 514 may include a color, a pattern, a combination of a color and a pattern, and the like.

[0054] In step 516, the second surface 115 of the first woven layer 114 is positioned adjacent to the first surface 312 of the nonwoven layer 310 to form a layered configuration. In step 518, a first entangling process 520, such as needlepunching, is performed in a first region of the layered configuration to at least partially form the pile zone 112. The first entangling process 520 is performed in a direction from the nonwoven layer 310 toward the first woven layer 114 to entangle the fibers / filaments 116 from the nonwoven layer 310 with the fibers / filaments / yarns of the first woven layer 114. In an exemplary embodiment, the first entangling process 520 may be performed once, although it is contemplated herein that the first entangling process 520 may be performed multiple times. Performing the first entangling step 520 in a direction from the nonwoven layer 310 toward the first woven layer 114 effectively secures or attaches the layers 114 and 310 to one another within the pile zone 112 due to increased fiber / filament availability within the nonwoven layer 310. In contrast, performing the entangling step in a direction from the first woven layer 114 toward the nonwoven layer 310 has been found to fail to secure the layers to one another due to decreased fiber / filament availability within the first woven layer 114. For example, when needlepunching is used as the entangling step, the needlepunching creates holes in the first woven layer 114 but generally fails to entangle the fibers / filaments / yarns from the first woven layer 114 with the fibers / filaments 116 of the nonwoven layer 310. Additionally, needlepunching has been found to effectively secure the first woven layer 114 to the nonwoven layer 310 relative to other mechanical entangling processes, such as hydroentangling. This is believed to be because hydroentanglement is unable to generate sufficient force to push the fibers / filaments 116 of the nonwoven layer 310 through and into the first woven layer 114 .

[0055] At step 522, the first woven fabric layer 114 is shown entangled with the nonwoven fabric layer 310 in the pile zone 112. As further shown, the fibers / filaments 116 from the nonwoven fabric layer 310 comprise a visual characteristic 514 (e.g., color), such that the visual characteristic 514 is visible on the first surface 113 of the first woven fabric layer 114 in the pile zone 112 due to the entanglement of the fibers / filaments 116 of the nonwoven fabric layer 310 with the fibers / filaments / yarns of the first woven fabric layer 114. At step 522, a second woven fabric layer 214 is provided. In an exemplary embodiment, the second woven fabric layer 214 includes a visual characteristic 524. The visual characteristic 524 may be the same as or different from the visual characteristic 512 and / or the visual characteristic 514. As above, the visual characteristic 524 may include a color, a pattern, a combination of color and pattern, and the like.

[0056] In step 526, the first surface 213 of the second woven fabric layer 214 is positioned adjacent to the second surface 314 of the nonwoven fabric layer 310 to form a layered configuration. In step 528, a second entangling step 530, such as needlepunching, is performed in an area of ​​the layered configuration corresponding to the pile zone 112. The second entangling step 530 is performed in a direction from the first woven fabric layer 114 to the second woven fabric layer 214 to entangle the fibers / filaments 116 of the nonwoven fabric layer 310, including the fibers / filaments 116 present in and on the first surface 113 of the first woven fabric layer 114, with the fibers / filaments / yarns of the second woven fabric layer 214. In an exemplary embodiment, the second entangling step 530 may be performed once, although it is contemplated herein that the second entangling step 530 may be performed multiple times. Similar to the first entangling process 520, needle punching, as opposed to other mechanical entangling processes such as hydroentangling, has been found to effectively secure the second woven fabric layer 214 to the nonwoven fabric layer 310, similar to the large amount of force that can be generated through the needle punching process.

[0057] Step 532 depicts the first surface 101 and the second surface 201 of the fabric 100. With respect to the first surface 101, and as described above, the insulation zone 110 generally comprises the visual characteristics 512 of the first woven fabric layer 114, and the pile zone 112 generally comprises a blend of the visual characteristics 512 of the first woven fabric layer 114 and the visual characteristics 514 of the nonwoven fabric layer 310. With respect to the second surface 201 of the fabric 100, the insulation zone 110 generally comprises the visual characteristics 524 of the second woven fabric layer 214, and the pile zone 112 generally comprises a blend of the visual characteristics 514 of the nonwoven fabric layer 310 and the visual characteristics 524 of the second woven fabric layer 214. The description of process 500 is exemplary only, and it is contemplated herein that the visual characteristics may differ from those depicted. For example, in some embodiments, the first woven fabric layer 114 and / or the second woven fabric layer 214 may be translucent or partially translucent, such that the visual characteristics 514 of the nonwoven fabric layer 310 are partially visible through the first woven fabric layer 114 and / or the second woven fabric layer 214 within the insulation zone 110 of the fabric 100. Additionally, the location, size, and shape of the insulation zone 110 and pile zone 112 may differ from those shown.

[0058] The described process 500 utilizes two woven layers, such as first woven layer 114 and second woven layer 214, and a nonwoven layer, such as nonwoven layer 310, to produce a fabric that includes both insulation zones and pile zones within a seamless configuration. Process 500 creates varied aesthetics between the insulation zones and pile zones on a particular surface of the fabric, as well as varied aesthetics on both the first and second surfaces of the fabric.

[0059] Fabric 100 can be incorporated into many different garments. For example, Figure 6 shows upper body garment 600 formed from fabric 100. Upper body garment 600 is shown in the form of a vest having a torso portion 610, a neck opening 612, a waist opening 614, a first arm opening 616, and a second arm opening 618. Although shown as a vest, it is contemplated herein that upper body garment 600 can be in the form of a sleeved jacket, pullover, shirt, hoodie, and the like.

[0060] The upper body garment 600 includes an insulating zone 620 corresponding to the insulating zone 110 of the fabric 100 and a pile zone 622 corresponding to the pile zone 112 of the fabric 100. The locations of the insulating zone 620 and the pile zone 622 may be based on, for example, a heat map of the human body. For example, the insulating zone 620 may be located in an area of ​​the upper body garment 600 corresponding to high heat loss of the wearer, such as the front upper torso and the back upper torso, and the pile zone 622 may be located in an area of ​​the upper body garment 600 corresponding to low heat loss, such as the front lower torso and the back lower torso. The size, shape, and number of the insulating zone 620 and the pile zone 622 on the upper body garment 600 are merely exemplary. In one exemplary embodiment, the upper body garment 600 may include multiple insulating zones and multiple pile zones. All embodiments, and any variations thereof, are considered to be within the scope of the present specification.

[0061] 7 shows a lower body garment 700 formed from fabric 100. Lower body garment 700 is in the form of pants having a torso portion 710 with a waist opening 712, a first leg portion 714 with a first leg opening 716, and a second leg portion 718 with a second leg opening 720. Although shown as pants, it is contemplated herein that lower body garment 700 may be in the form of shorts, tights, capris, unitards, and the like.

[0062] The lower-body garment 700 includes insulation zones 722 located in the torso portion 710 and in the lower portions of the first leg portion 714 and the second leg portion 718. Pile zones 724 are located in the upper and middle portions of the first leg portion 714 and the second leg portion 718. The locations of the insulation zones 722 and the pile zones 724 may be based on a heat map of the human body. The size, shape, and number of the insulation zones 722 and the pile zones 724 are exemplary.

[0063] Although not shown, it is contemplated that the fabric 100 may be used to form additional articles such as hats, gloves, extremity sleeves, socks, uppers, and the like.

[0064] 8 is a flow diagram of an exemplary method 800 for manufacturing a woven fabric, such as woven fabric 100. In step 810, a nonwoven layer, such as nonwoven layer 310, is positioned between a first woven layer, such as first woven layer 114, and a second woven layer, such as second woven layer 214, to form a layered configuration. In step 812, fibers and filaments from the nonwoven layer are entangled with fibers, filaments, and / or yarns from the first and second woven layers, respectively, in a first region of the layered configuration to form a pile zone. As used herein, the entanglement step is not performed in a second region of the layered configuration, corresponding to the thermal insulation zone; as a result, the first woven layer, second woven layer, and nonwoven layer are considered to comprise separate and distinct layers.

[0065] Embodiments herein further contemplate that the nonwoven layer is formed by intertwining fibers and filaments from two or more nonwoven sheets, as described with respect to step 400.

[0066] 5, step 812 may include positioning a first woven fabric layer adjacent to a first surface of the nonwoven fabric layer and performing a first entangling step in a direction from the nonwoven fabric layer toward the first woven fabric layer. After completing the first entangling step, a second woven fabric layer is positioned adjacent to a second, opposite surface of the nonwoven fabric layer. A second entangling step is then performed in a direction from the first woven fabric layer toward the second woven fabric layer to complete the formation of the pile zone.

[0067] As described with respect to steps 400 and 500, the visual properties of the nonwoven sheet used to form the nonwoven layer can be selected to achieve the desired visual properties of the nonwoven layer. In addition, the visual properties of the first and second woven layers can be selected to achieve the desired visual properties of the insulation zone(s) and pile zone(s) on a first surface of the fabric and the desired visual properties of the insulation zone(s) and pile zone(s) on a second, opposing surface of the fabric. The visual properties of the fabric can also be adjusted based on the degree of entanglement of the nonwoven sheet used to form the nonwoven layer and the degree of entanglement of the nonwoven layer with the first and second woven layers, respectively.

[0068] Aspects of the present disclosure have been described with the intent to be illustrative and not limiting. Alternative aspects will be apparent to those skilled in the art without departing from its scope. Those skilled in the art may develop alternative means of implementing the improvements described above without departing from the scope of the present disclosure.

[0069] It will be understood that certain features and subcombinations are practical and may be employed without regard to other features and subcombinations and are contemplated within the scope of the claims. Not all steps listed in the various figures need be performed in the particular order described.

Claims

1. A woven fabric, an insulating zone comprising a first woven fabric layer, a second woven fabric layer, and a nonwoven fabric layer positioned between the first and second woven fabric layers and including a plurality of fibers / filaments; an insulating zone, wherein each of the first and second woven fabric layers is not attached to the nonwoven fabric layer in the insulating zone; a pile zone extending seamlessly from the insulation zone; a pile zone comprising the first woven fabric layer, the second woven fabric layer, and the nonwoven fabric layer positioned between the first woven fabric layer and the second woven fabric layer; Equipped with In the pile zone, the plurality of fibers / filaments are entangled with the first and second woven fabric layers and extend through each of them to the outside of the fabric; As a result, the first and second woven fabric layers are bound to the nonwoven fabric layer, and the numerous fibers / filaments extending outside the fabric give the pile zone a texture different from that of the insulation zone. Woven fabric.

2. the nonwoven layer comprises two or more nonwoven sheets; the fibers / filaments from each of the two or more nonwoven sheets are entangled with one another; The fabric of claim 1.

3. a first nonwoven sheet of the two or more nonwoven sheets having a first visual characteristic; a second nonwoven sheet of the two or more nonwoven sheets having a second visual characteristic different from the first visual characteristic; The fabric of claim 2.

4. the first visual characteristic comprises a first color; the second visual characteristic comprises a second color. The fabric of claim 3.

5. the first visual characteristic comprises a first pattern; the second visual characteristic comprises a second pattern.

5. The fabric according to claim 3 or 4.

6. the nonwoven layer has a weight of 180 grams per square meter (gsm) to 220 gsm; The fabric according to any one of claims 1 to 5.

7. A garment formed using the fabric according to any one of claims 1 to 6.

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