Seamless Double Layered Porous Woven Structure

Abstract

A seamless double layered porous woven structure comprises a seamless circular inner layer structure and a porous outer layer structure. The outer layer structure is weaved upon the seamless circular inner layer structure to provide a seamless double layered tubular structure, which is further gaited together with yarns at the edges of the double layered tubular structure. The inner layer structure is made of circular weaving process while the outer layer structure is made of warp weaving process. There are several porous regions and jacquard regions at the outer layer structure.

Claims

1. A seamless double layered porous woven structure comprises a seamless circular inner layer structure and a porous outer layer structure; wherein the outer layer structure is weaved upon the seamless circular inner layer structure to provide a seamless double layered tubular structure; wherein the edges of the double layered tubular structure are grafted together by yarns into one piece.

2. The seamless double layered porous woven structure of claim 1, wherein the inner layer structure is made of circular weaving process while the outer layer structure is made of warp weaving process; wherein there are several porous regions and jacquard regions at the outer layer structure.

3. The seamless double layered porous woven structure of claim 2, wherein the porous regions are made with warp weaving machine based on a weaving plan including weaving density and pore arrangement; wherein warp weaving machine has a crochet needle flipping device which flips yarn loops at up(down) or left(right) crochet needle bed to down(up) or right(left) crochet needle bed to create braided structure around the pores and reinforce the pore edges.

4. The seamless double layered porous woven structure of claim 2, wherein the porous regions are created by warp weaving technology by loop transfer and/or crochet needle flipping methods to snag yarns to form braided structure.

5. The seamless double layered porous woven structure of claim 1, wherein there are pores on both the inner layer structure and outer layer structure; wherein the pores may be at same exact locations or different locations of the double layered tubular structure to create penetrated through holes or half-through holes.

6. The seamless double layered porous woven structure of claim 1, wherein there are several jacquard regions with same or different jacquard patterns on both the inner layer structure and outer layer structure.

7. The seamless double layered porous woven structure of claim 1, wherein both the inner layer structure and outer layer structure are made of yarns selected from natural fibers, naturally synthesized fibers, recycled fibers, synthetic fibers or the combinations of above materials; wherein the fibers can be single fiber yarn, elastic fiber yarn, hot melt yarn; wherein the yarns have functions like UV blocking, anti-bacteria, thermal barrier, air penetration, conductive metal fiber, phosphorescent or photo absorption properties.

8. The seamless double layered porous woven structure of claim 1, wherein the inner layer structure is made of circular weaving method with multiple color yarns to produce tubular structure with protruded pores and jacquard regions.

9. The seamless double layered porous woven structure of claim 1, wherein the inner layer structure and outer layer structure are both double layered structures in either separated or integrated form.

10. A seamless sports bra comprises a seamless stereobate, a circular inner layer structure and a porous outer layer structure; wherein the outer layer structure is weaved upon the seamless circular inner layer structure to provide a seamless double layered chest shape structure with integrated shoulder straps; wherein the ends shoulder straps are grafted together by yarns into one piece.

11. The seamless double layered porous woven structure of claim 1, wherein the inner layer structure and/or outer layer structure have patterns of UV ink printing or digital printing to create regional visual jacquard effect.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0029] FIG. 1 shows the front schematic diagram of a seamless double layered porous woven structure.

[0030] FIG. 2 shows the back schematic diagram of a seamless double layered porous woven structure.

[0031] FIG. 3 shows the schematic diagram of the A-A cross section of a seamless double layered porous woven structure in FIG. 2.

[0032] FIG. 4 shows the schematic diagram of the B-B cross section of a seamless double layered porous woven structure in FIG. 2.

EMBODIMENTS

[0033] Example embodiment of the present invention is described below. However, the present invention should be in no way restricted by the examples.

[0034] A seamless sports bra was used as an example to illustrate our technology. FIG. 1 shows the front schematic diagram of a seamless double layered porous woven structure. Cotton yarns containing 10% elastic fibers were used for circular weaving to produce an inner layer structure 1 and a seamless elastic woven stereobate 3. Warp weaving was applied on top of the inner layer structure 1 to create an outer layer structure 2. Based on a weaving plan with weaving density and pore density distribution, the warp weaving machine has a needle transfer device to flip the yarn loops from up(down) or left(right) crochet needle bed to down(up) or right(left) crochet needle bed to create pores with braided yarn around them for pore edges reinforcement. Both the inner layer structure 1 and the outer layer structure 2 are seamless tubular chest shape with integrated shoulder straps, which were, grafted together by stitched yarns. A cloth strip was used to form a bordure and covered both the inner layer structure 1 and the outer layer structure 2; and thus a double layered sports bra was created with chest area being seamless.

[0035] A circular weaving plan with weaving density and pore density distribution was created. The circular machine was equipped with several needle selectors and modified with needle flipping devices. Based on the plan, several woven regions and several porous regions were formed. The woven regions were accomplished by multiple needle selectors with multiple yarns twisted into multiple loops based on pre-determined weaving density. The porous regions were accomplished by a modified crochet needle transfer and flipping device to braid the newly created yarn loops nearby, at left right up and down, into pores based on pre-determined pore density. The modified crochet needle transfer and flipping device was created to snag the yarns loops nearby, at left right up and down, for braiding and created holes and patterns based on pre-determined pore density design and provided a colorful jacquard woven product. The resulting woven products can be further decorated by externally laminated patterns or digital printing with UV ink to provide regional jacquard with stereoscopic visual effect for 3D logo or 3D pattern applications.

[0036] FIG. 2 shows the back schematic diagram of a seamless double layered porous woven structure. There is no fastener needed at the back of the sports bra example. The front and the back structures are in one piece. The ends of front and back shoulder straps were attached as a grated line 4 at the back shoulder to be less visible. As shown in FIG. 3 the A-A cross section shows that both inner layer structure 1 and the outer layer structure 2 of sports bra are in seamless tubular shape at the chest area.

[0037] In FIG. 4, the B-B cross section shows that the bordure is located at edge of the bra. A strip of fabric is usually used create bordure to eliminate the discomfort from the edges of woven structure.

[0038] Moreover, as those of skill in this art will appreciate, many modifications, substitutions and variations can be made in and to a method of making light guiding decorative composite sheet or components of these example embodiments without departing from its spirit and scope. In light of this, the scope of the present invention should not be limited to that of the particular embodiments illustrated and described herein, as they are only exemplary in nature, but instead, should fully commensurate with that of the claims appended hereafter and their equivalents.

DESCRIPTION OF KEY ELEMENTS

[0039] 1: inner layer structure [0040] 2: outer layer structure [0041] 3: elastic woven stereobate [0042] 4: grafted line [0043] 5: bordure