MULTILAYER WEAVING FOR SEAMLESS APPAREL PRODUCTION

Description

CROSS-REFERENCE

This application claims the benefit of U.S. Provisional Patent Application Ser. No. 63/692,269 filed on Sep. 9, 2024, which is incorporated herein by reference in its entirety.

TECHNICAL FIELD

The invention relates to three-dimensional (3D) seamless woven structures that have a main tubular section transitioning to two or more tubular sections. In its simplest form, the woven structure is a bifurcated tubal structure, for example, a pair of pants. Depending upon the size and the material used, the seamless woven structure can be apparel, medical implants, medical devices, plumbing parts, machine parts, etc.

BACKGROUND

Annually, textile production emits 1.2 billion tons of greenhouse gases and uses approximately 93 billion cubic meters of water. When factoring in the growth of emerging markets, it is projected that the textile sector will be responsible for over 25% of the world's carbon budget by 2050 without substantial intervention (Ellen McArthur Foundation, 2017). Currently, apparel production represents over 60% of all textile use. Offcut waste produced during apparel manufacturing accounts for at least 25% of apparel textile usage leading to an opportunity loss worth approximately $10 billion a year (Ellen McArthur Foundation, 2017). While the knitting segment has developed technology, such as Shima Seiki's Wholegarment® and Stoll's Knit & Wear® systems, capable of knitting fully constructed garments in one piece and eliminating up to 40 production steps, the weaving segment has been unable to develop and implement equivalent industrial innovations.

In 2021, the global apparel market reached $1.5 trillion and is projected to reach $2 trillion by 2026. According to the Ellen McArthur Foundation, 1.2 billion pairs of jeans are purchased annually. In 2020, the global denim market was valued at $73.09 billion, with a 6.81% projected CAGR. Denim, used to produce jeans, is a woven fabric. Key driving factors include growth in the target population across the globe and a rise in consumer disposable income levels, specifically in emerging countries like India and China. Growth in consumer demand for sustainably manufactured goods adds to the market value as well.

An embodiment of the present invention, a seamless woven structure in the form of a bifurcated tube is directly applicable to improving the process for making pants. There is a need to reduce waste in apparel production. There is a need to reduce the labor-intensive sewing required in apparel production. There is a need to be able to produce seamless woven structures on existing weaving machines (looms).

Additionally, weaving technology has uses well beyond apparel. Weaving technology is used to make products as diverse as medical implants, medical devices, plumbing parts, automotive parts, machine parts, etc. Wherever a split-tubal structure is required, there is a need for a simpler, more environmentally friendly, and less expensive process for making split-tubal seamless woven structures that are bifurcated, tri-furcated, etc.

SUMMARY OF THE INVENTION

In some aspects, the techniques described herein relate to a process for making a branched tubal structure, the process including weaving the branched tubal structure in at least four layers. The at least four layers are stacked on a weaving machine, and the branched tubal structure includes a first section connected to a second section. The first section includes each of the at least four layers connected in a larger tube, and the second section includes sequential pairs of the at least four layers connected in at least two smaller tubes.

In some aspects, the techniques described herein relate to a process for making a bifurcated tubal structure. The process including: weaving the bifurcated tubal structure in four layers, wherein the four layers are stacked on a weaving machine. The bifurcated tubal structure includes a first section connected to a second section. The first section includes each of the four layers connected in a larger tube, and the second section includes sequential pairs of the four layers connected in two smaller tubes.

In some aspects, the techniques described herein relate to a process for making a bifurcated tubal structure, the process including: (a) setting a warp sheet including warp yarns on a weaving machine; (b) dividing the warp yarns between at least 8 harnesses, wherein four sets of warp yarns are distributed among the at least 8 harnesses, and wherein the four sets of warp yarns correspond to four layers of woven fabric, L1, L2, L3, and L4; (c) implementing a first sequence of at least 8 sheds, wherein a first weft yarn is inserted into each of the four layers in a first order that connects the four layers of woven fabric in a larger tube, and optionally implementing a modified first sequence of the at least 8 sheds, wherein the first weft yarn is inserted into each of the four layers in a modified first order that connects the four layers of woven fabric in the larger tube and wherein at least two of the four layers are not continuously connected; (d) repeating step c) until the larger tube is formed to a first desired length; (e) implementing a second sequence of at least 8 sheds, wherein a second weft yarn is inserted into each of the layers L1 and L2 and a third weft yarn is inserted into each of the layers L3 and L4, in a second order that connects the layers L1 and L2 in a first smaller tube and the layers L3 and L4 in a second smaller tube, and optionally implementing a modified second sequence of the at least 8 sheds wherein the second weft yarn is inserted into each of the layers L1 and L2 and a third weft yarn is inserted into each of the layers L3 and L4, in a modified second order that connects the layers L1 and L2 in a first smaller tube, the layers L3 and L4 in a second smaller tube, and wherein the layers L1 and L2 and/or the layers L3 and L4 are not continuously connected; and (f) repeating step e) until the first smaller tube and the second smaller tube are a second desired length. The larger tube is folded while on the weaving machine, and the first smaller tube and the second smaller tube are staked while on the weaving machine. A movement of the at least 8 harnesses in step c) is set by the first sequence of the at least 8 sheds and optionally the modified first sequence of the at least 8 sheds, and the movement of the at least 8 harnesses in step e) is set by the second sequence of at least 8 sheds and optionally by the modified second sequence of the at least 8 sheds. The larger tube is connected to the first smaller tube and the second smaller tube.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure is illustrated and described herein with reference to the various drawings, in which like reference numbers are used to denote like system components/method steps, as appropriate, and in which:

FIG. 1 is a schematic illustration of the difference between traditional cut and sew manufacturing and seamless manufacturing;

FIG. 2a is a side perspective view and FIG. 2b is a top view of a simple schematic of an example weaving machine;

FIG. 3a is a perspective view of a series of schematics depicting the shedding, weft insertion, and beat-up motions of shuttle weaving, FIG. 3b is a perspective view of a series of schematics depicting the shedding, weft insertion, and beat-up motions of shuttleless weaving;

FIG. 4a is a top view schematic of a woven fabric produced using shuttle weaving with the continuous weft yarn going back and forth over the warp sheet and forming a bound savage on each side of the woven fabric, FIG. 4b is a top view schematic of a woven fabric produced using shuttleless weaving with the weft yarn cut, producing a fringed selvage, FIG. 4c and FIG. 4d are top view schematics of woven fabrics with leno selvages and tucked-in selvages, respectively;

FIG. 5a is a schematic of a non-limiting embodiment of a folded bifurcated structure, pants, FIG. 5b is a cross-section view of the pants in FIG. 5a along A-A of the waist section, FIG. 5c is a cross-section view of the pants in FIG. 5a along B-B of the leg section;

FIG. 6 is a graphical representation of one repeat of the weave design, DID (drawing-in-draft) and chain (or lift) plan on square paper for the larger tube in plain weave;

FIG. 7 is a schematic of a warp sheet cross-section view of the folded tube being formed by shuttle weaving in a plain weave;

FIG. 8 is a schematic of a top view of the unfolded waist section showing the waist edge exhibiting continuous plain weave;

FIG. 9 is a schematic of a warp sheet cross-section view of the two smaller tubes being formed by shuttle weaving in a plain weave;

FIG. 10 is a second graphical representation of one repeat of the weave design, DID (drawing-in-draft) and chain (or lift) plan on square paper for forming the two smaller tubes in plain weave;

FIG. 11a is a front perspective view of pants, FIG. 11b is a schematic of a top view of the waist section of the pants shown in FIG. 11a cut along the L1, L4 interface and laid out flat, showing an example of continuous twill weave pattern match;

FIG. 12 is a schematic of a top view of the unfolded waist section of the pants (not shown), cut at the L1/L4 interface and laid flat, showing the continuous jacquard weave pattern match;

FIG. 13 is a front view of prototype pants, shown in unfolded form;

FIG. 14 is a back view of prototype pants that was produced on a Thread Controller 2 (TC2) jacquard weaving machine (loom);

FIG. 15 is a front view of prototype pants made with an opening starting at the front-center waist edge;

FIGS. 16a-16c are a top view of the waist section, a cross-section view of the waist section below the opening, and a cross-section view in the leg section of the prototype pants of FIG. 15 when formed folded on the weaving machine (not shown);

FIG. 17a is a front perspective view of a prototype pocket made with an opening starting at the waistline of pants (not shown); FIG. 17b is a cross-section view of the modified folded tube with six layers.

DETAILED DESCRIPTION

In some aspects, the techniques described herein relate to a process for making a branched tubal structure, the process including weaving the branched tubal structure in at least four layers. The at least four layers are stacked on a weaving machine, and the branched tubal structure includes a first section connected to a second section. The first section includes each of the at least four layers connected in a larger tube, and the second section includes sequential pairs of the at least four layers connected in at least two smaller tubes.

The present invention may be understood more readily by reference to the following detailed description of the invention taken in connection with the accompanying drawing figures, which form a part of this disclosure. It is to be understood that this invention is not limited to the specific devices, methods, conditions or parameters described and/or shown herein, and that the terminology used herein is for the purpose of describing particular embodiments by way of example only and is not intended to be limiting of the claimed invention. Any and all patents and other publications identified in this specification are incorporated by reference as though fully set forth herein

Also, as used in the specification including the appended claims, the singular forms “a,” “an,” and “the” include the plural, and reference to a particular numerical value includes at least that particular value, unless the context clearly dictates otherwise. Ranges may be expressed herein as from “about” or “approximately” one particular value and/or to “about” or “approximately” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another embodiment.

It is to be understood that the mention of one or more method steps does not preclude the presence of additional method steps before or after the combined recited steps or intervening method steps between those steps expressly identified. Moreover, the lettering of method steps or ingredients is a conventional means for identifying discrete activities or ingredients and the recited lettering can be arranged in any sequence, unless otherwise indicated.

As used herein, the term “and/or”, when used in a list of two or more items, means that any one of the listed items can be employed by itself, or any combination of two or more of the listed items can be employed. For example, if a composition is described as containing compounds A, B, “and/or” C, the composition may contain A alone; B alone; C alone; A and B in combination; A and C in combination; B and C in combination; or A, B, and C in combination.

As used herein, the term “branched tubal structure” refers to any 3D product made on a weaving machine (loom) with one larger tube connected to at least two smaller tubes. The term “bifurcated tubal structure” refers to a “branched tubal structure” with two smaller tubes. As used herein, the term “seamless branched tubal structure” refers to any 3D structure made on a weaving machine (loom) that has a 3D structure and no sewing seams.

As used herein, the term “stacked,” as in “four layers are stacked during weaving,” refers to the four layers being woven with a first layer on top of a second layer, the second layer on top of a third layer, and the third layer on top of a fourth layer.

As used herein, the term “first section” refers to the part of the “branched tubal structure” that is a tube made from all of the layers on the weaving machine. The “first section” of pants may be referred to as the “waist section.” As used herein, the term “second section” refers to the part of the “branched tubal structure” made up of smaller tubes, each made from two connected layers on the weaving machine. The “second section” of pants may be referred to as the “leg section.”

As used herein, the term “a first section connected to a second section” refers to the connection between the first section and the second section being formed through the weaving process itself.

As used herein, the term “continuously connected,” as in two layers are “continuously connected,” refers to there being no openings between the two layers, the two layers are one continuous tube. As used herein, the term “not continuously connected,” as in two layers are “not continuously connected” refers to there being a gap in the connection between the two layers. The gap can be at the top of the first section and/or bottom section, at the bottom of the first section and/or the second section, or in the middle of the first section and/or the second section.

As used herein, the term “sectionally continuous weft yarn” refers to the use of a weft yarn that is continuous throughout a section. For example, moving a shuttle back and forth to form a tube between 2 or 4 layers of warp yarns.

In some aspects, the techniques described herein relate to the seamless manufacturing of pants. FIG. 1 is a schematic illustration of the difference between traditional cut and sew manufacturing 100 and seamless manufacturing 130. Traditional cut and sew manufacturing 100 requires labor-intensive processes that include turning yarn 110 into textile 112, cutting textile 112 into pattern pieces 114 (with offcut waste 116), and using sewing equipment 118 to assemble the pattern pieces 114 into a completed garment 120. These traditional cut and sew manufacturing 100 processes are time-consuming, add to production costs, and create a high volume of offcut waste 116. In contrast, if a completed garment 120 can be produced directly from the yarn 110, which does not require assembly, as depicted in the seamless manufacturing 130 of FIG. 1, the cost of manufacturing and the resulting offcut waste 116 can be dramatically reduced

Introduction to Weaving

In its simplest form, woven fabric is structured from a single layer (two-dimensional or 2D) of two orthogonal sets of yarns; namely warp and weft yarns. The warp and weft yarns are interlaced (or interwoven) in different ways referred to as weave designs. The basic weave designs are plain weave and its derivatives, twill weaves and their derivatives, and satin/sateen weaves and their derivatives. Combined with colored yarns and/or special effects and functional yarns, the basic weaves are utilized to produce an unlimited number of intricate woven fabrics (simple, dobby, and jacquard patterns) for fashion and performance applications. Post weaving, single layer woven fabrics are converted to three-dimensional (3D) by stacking and needle stitching and/or cut and sew processes to obtain performance requirement and fashionable fit in the case of apparel. These techniques lead to dramatic waste, high cost of labor, and reduction in the final product performance as a result of needle holes and fiber damage. These drawbacks led to the development of techniques to weave multilayer (3D) structures, including seamless products for fashion and technical applications.

FIG. 2a shows a side perspective view and FIG. 2b shows a top view of a simple schematic of an example weaving machine 150. The warp yarn 110a comes off of warp beam 152, around whip roller (or backrest) 154, and through drop wires 156 to form the warp sheet 158. The weaving machine 150 performs four primary motions to weave a fabric, these are (1) shedding, (2) weft insertion, (3) beat up, and (4) warp and fabric control. To weave a weft yarn (not shown), filling or pick, the following sequential events are performed: (1) a shed 160 is formed as a result of moving the harnesses H1-H8 (up or down) according to the weave design, (2) a weft yarn (not shown) is inserted into the shed 160 by a filling insertion means (not shown), (3) the reed 162 moves to beat-up the newly inserted weft yarn (not shown) and incorporate it into the woven fabric 164 as the cloth fell 166 (last weft woven), and (4) the warp sheet 158 is fed (let-off) from the warp beam 152 through the weaving machine 150 and the woven fabric 164 travels though the fabric take up rolls 168 and is collected onto the cloth roll 170. The four sequential events are repeated to produce the required fabric length. Using the four primary motions, a weaving machine 150 is capable of forming single layer (2D) or multilayer (3D) fabrics depending on weave design that dictates the number of harnesses, which are controlled by the shedding mechanism.

FIG. 3a shows a profile view of a series of schematics depicting the shedding 200, weft insertion 210, and beat-up motions 220 of shuttle weaving. A shed 160 is formed in the shedding 200, the shuttle 230 moves across the warp sheet 158 within the shed 160 in the weft insertion 210, and the reed 162 is used to move the weft yarn 110b into the cloth fell 166 in the beat-up motions 220. In shuttle weaving, the weft package (known as quill) is carried by the shuttle 230 that provides continuous weft yarn and consequently a bound selvage. FIG. 3b shows a schematic depicting the shedding 200, weft insertion 210, and beat-up motions 220 of shuttleless weaving. As shown in FIG. 3b the shed 160 is formed in the shedding 200, the projectile means 232 launches the projectile 234 which carries the weft yarn 110b across the warp sheet 158 within the shed 160 in the weft insertion 210, and the reed 162 is used to move the warp yarn 110b into the cloth fell 166 in the beat-up motions 220. In shuttleless weaving, the weft insertion means (projectile, air/water jet, and rapier) pick up the end from the stationary weft yarn package 232 and after each insertion the weft yarn 110b is cut, consequently, a fringed selvage is formed.

FIG. 4a through FIG. 4d show schematics of woven fabrics and the selvages produced from different types of weaving. FIG. 4a shows a woven fabric 164 produced using shuttle weaving with the continuous weft yarn 110b going back and forth over the warp sheet 158 and forming a bound selvage 252 on each side of the woven fabric 164. FIG. 4b shows a fabric produced using shuttleless weaving with the weft yarn 110b cut, producing the fringed selvage 254. The fringed selvage 254 is vulnerable to fraying. FIG. 4c and FIG. 4d show the leno selvage 256 and the tucked-in selvage 258, respectively, which are two non-limiting ways to decrease fraying in the fringed selvage 254. The leno selvage 256 is formed by turning the yarns to change their order that provide high frictional force with the weft yarns 110b and hence the warp yarns 110a are secured from fraying. The tucked-in selvage 258, provide bounding of warp yarns 110a by looping around the last and first warp yarn 110a in the fabric 164.

Formation of Folded Bifurcated Structure Using Shuttle Weaving Technology

Here, a description of forming folded bifurcated structure in detail is given. A person skilled in the art of weaving can extended the description of forming a folded bifurcated structure to the formation of folded trifurcated, quadfurcated, etc. structures. Traditionally, seamless woven bifurcated fabrics (defined as a tube that separates into two tubes) are used as replacement of diseased arteries. More recently, seamless bifurcated structures are proposed for apparel articles. The current art of forming seamless bifurcated articles is using a shuttle weaving machine with at least two shuttles. This requires weaving the main tube by one of the shuttles and then splitting the warp sheet into two situated at different heights to weave the branched tubes side-by-side. The current invention discloses the formation of folded bifurcated, trifurcated, quadfurcated, etc. structures and potential end uses. The main tube is woven in folded configuration, and it branches into two, three, four, etc. tubes formed one on the top of the other. This strategy allows the construction of seamless folded bifurcated, trifurcated, quadfurcated, etc. structures using shuttle weaving machine using single or multiple insertion as the warp width on loom and consequently each weft length is constant throughout the formation process.

FIGS. 5a-5c show different views of a schematic of a non-limiting embodiment of a folded bifurcated structure, pants 300 as they are produced on the weaving machine. FIG. 5a shows a bottom perspective view of the pants 300 along their length. Looking up from the bottom of the loom layer 4 (L4) is below L3 which is below L2 which is below L1. The pants 300 are divided into two distinct parts, the leg section 310 and the waist section 312, along the pants 300 length. The top of the waist section 312 is the waist edge 314 and the bottom of the waist section 312 is the crotch line 316. The top of the leg section 310 is the crotch line 316 and the bottom of the leg section 310 is the hem edge 318. FIG. 5b is a cross-section view of the pants 300 in FIG. 5a along A-A of the waist section 312. Waist section 312 is the folded tube 320 formed from four woven layers, L1, L2, L3, and L4. FIG. 5c is a cross-section view of the pants 300 in FIG. 5a along B-B of leg section 310. The two branched tubes 322a and 322b of the leg section 310 are formed with one on the top of the other from the same four layers L1-L4. The first smaller tube 322a is formed from layers L1 and L2 and the second smaller tube 322b is formed from layers L3 and L4. This strategy provides a continuous cavity to access the pant 300 by a wearer (not shown). The folded tube 320 of waist section 312 may be woven using one shuttle (not shown) as a minimum while the smaller tubes 322a and 322b of the leg section 310 require two shuttles (not shown) as a minimum. The shuttle (not shown) used to form the folded tube 320 may be used to weave one of the smaller tubes 322a or 322b. More shuttles would be used if different weft yarns with different potential shrinkage and/or colored yarns are used to produce shaped bifurcated structures with different dimensions along the pants 300 length and colored patten enhancement for fashion along each of folded tube 320, first smaller tube 322a, and/or second smaller tube 322b.

The minimum number of harnesses required to weave a folded bifurcated product (e.g., the pants 300) is 8 with 2 harnesses dedicated to each of the four layers, L1-L4, if a woven structure of plain weave (or one or more of its derivatives) is desired. Each harness controls a part of the total number of warp yarns 110a of the warp sheet. Assuming forming a folded bifurcated structure with all layers in plain weave and same structure parameters, in this case the warp sheet is divided to 8 sheets of warp yarns. Slight adjustment to the number of ends in one or more sheets is used so that the product to show weave or pattern match on the unfolded product. FIG. 2a and FIG. 2b show a weaving machine 150 with 8 harnesses, labeled H1-H8 controlling 8 sub-sheets of warp, set to weave folded bifurcated woven structure. The folded bifurcated fabric can be woven starting from the waist edge 314 or from the hem edge 318. The description given below assumes the weaving is started from the waist edge 314 to weave the four layers of folded tube 320 then weaving the two smaller tubes 322a and 322b.

FIG. 6 shows a graphical representation of one repeat (8 warp yarns 110a and 8 weft yarns 110b) of the weave design, DID (drawing-in-draft) and chain (or lift) plan on square paper for forming four layers in plain weave. The assignments of warp yarns to layers and harnesses are shown. For example, warp yarns 1 and 5 are assigned to layer L1, warp yarns 2 and 6 are assigned to layer L2, etc. Warp yarns 1-8 are assigned to harness 1-8 as seen in the DID, and warp yarns 9-16 (not shown) are assigned to harness 1-8, etc., which means that the warp sheet is divided to 8 sub-sheets S1-S8 and every two sub-sheets are assigned to weave one layer of the four-layer structure. Sub-sheets S1 and S5 are controlled by harnesses 1 and 5 to weave layer L1, sub-sheets S2 and S6 are controlled by harnesses 2 and 6 to form layer L2, etc.

FIG. 7 is a schematic of a cross-section view of the folded tube 320 being formed by shuttle weaving in a plain weave. Warp yarns 110a are shown in white circles and weft yarns 110b are shaded in dark grey. Each of the four layers (L1-L4) is woven from two sub-sheets of the warp sheet 158 and each is independently controlled by a harness (H1-H8). The number of sub-sheets is 8 and labeled S1-S8. The first layer in plain weave (top layer) L1 is formed from sub-sheets S1 and S5 that are controlled by harnesses H1 and H5, respectively. The second layer in plain weave L2 is formed from sub-sheets S2 and S6 that are controlled by harnesses H2 and H6. The third layer in plain weave L3 is formed from sub-sheets S3 and S7 that are controlled by harnesses H3 and H7. The fourth layer in plain weave L4 is formed from sub-sheets S4 and S8 that are controlled by harnesses H4 and H8. The number of weft yarns 110b per repeat is 8 and requires 8 weaving cycles, including 8 weft insertions. A non-limiting example starting point of weaving the folded tube using shuttle weft insertion is shown in FIG. 6. The weft yarns sequence to form the folded tube 320 is to weave the first weft yarn 110b in layer L1 from left to right, the second weft yarn 110b in layer L2 from right to left, the third weft yarn 110b in layer L3 from left to right, the fourth weft yarn 110b in layer L4 from right to left, the fifth weft yarn 110b in layer L1 (to complete the plain weave repeat of L1) from left to right, the sixth weft yarn 110b in layer L2 from right to left, the seventh weft yarn 110b in layer L3 from left to right, and the eighth weft yarn 110b in layer L4 from right to left. One skilled in the art recognizes that the first through the eighth weft yarns 110b are one continuous yarn and are differentiated to describe the order of weft insertions. This sequence is repeated until the desired length of waist section 312 is achieved. The starting point is not limited to the aforementioned sequence.

The 8 sheds 160 corresponding to the 8 weft insertions are formed according to the lift plan of FIG. 6 as described below. The first shed 160 is formed by raising harness H1 and lowering harnesses H2-H8 as seen in FIG. 1. The second shed 160 is formed by raising harnesses H1 and H5-H6 and lowering harnesses H2-H4 and H7-H8. The third shed 160 is formed by raising harnesses H1-H3 and H5-H6 and lowering harnesses H4 and H7-H8. The fourth shed 160 is formed by raising harnesses H1-H3 and H5-H8 and lowering harness H4. The fifth shed 160 is formed by raising harness H5 and lowering harnesses H1-H4 and H6-H8. The sixth shed 160 is formed by raising harnesses H1-H2 and H5 and lowering harnesses H3-H4 and H6-H8. The seventh shed 160 is formed by raising harnesses H1-H2 and H5-H7 and lowering harnesses H3-H4 and H8. The eighth shed 160 is formed by raising harness H1-H7 and lowering harness H8.

A minor adjustment to the number of ends in one or more sheets is useful for the product to show weave or pattern match on the unfolded product (e.g., folded tube 320). FIG. 7 shows that the number of warp yarns 110a in layer L4 is less by one compared to the number of warp yarns 110a in each of the three layers L1, L2, or L3. FIG. 8 is a schematic of a top view of the unfolded waist section 312 showing the waist edge 314 exhibiting continuous plain weave. FIG. 8 shows the results of the adjustment in the number of warp yarns in layer L4. As the weft yarn 110b starts a location 350 of L1 and travels left to right, L2 starts at location 352 with the weft yarn 110b traveling right to left, L3 starts at location 354 with the weft yarn 110b traveling left to right, and L4 starts at location 356 with the weft yarn 110b traveling right to left. The unfolded tube post shuttle weaving exhibits plain weave structure. If the adjustment is not done, two yarns will be woven together, while in plain weave every yarn is woven individually. Two yarns woven together will show as a defect which will affect the appearance and performance. The adjustment could be done by increasing the number of yarns in layer L4 by one compared to the number of warp yarns in each of the three layers L1, L2, or L3. It is noted that for pattern match, the total number of warp yarns to form the tube in plain weave is an odd number.

Once waist section 312 reaches its desired length, the formation of the leg section 310 starts using two shuttles as a minimum. FIG. 9 is a schematic of a warp cross-section of the smaller tubes 322a and 322b being formed by shuttle weaving in a plain weave. Warp yarns 110a are shown in white circles and weft yarns 110b are shaded in dark grey. The two smaller tubes 322a and 322b of leg section 310 are formed with one on the top of the other from the same four layers L1-L4. One of the smaller tubes 322a is formed from layers L1 and L2 while the other of the smaller tubes 322b is formed from layers L3 and L4. The assignments of warp and weft yarns to layers are the same as seen in FIG. 6. The number of weft yarns (insertion cycles) per weave repeat is the same as weaving waist section 312 that requires 8 sheds corresponding to the 8 weft insertions described below. The number of warp yarns 110a in layer L2 for the first smaller tube 322a is one less than the number of warp yarns 110a in layer L1 for the first smaller tube 322a to match the pattern weave.

The first shed 160 is formed by raising harness H1 and lowering harnesses H2-H8 and shuttle 1 moves from left to right to weave the first weft yarn 110b in layer L1. The second shed 160 is formed by raising harnesses H1 and H5-H6 and lowering harnesses H2-H4 and H7-H8 and shuttle 1 moves from right to left to weave the second weft yarn 110b in layer L2. The third shed 160 is formed by raising harnesses H1-H3 and H5-H6 and lowering harnesses H4 and H7-H8 and shuttle 2 moves from left to right to weave third weft yarn 110b in layer L3. The fourth shed 160 is formed by raising harnesses H1-H3 and H5-H8 and lowering harness H4 and shuttle 2 moves from right to left to weave the fourth weft yarn 110b in layer L4. The fifth shed 160 is formed by raising harness H5 and lowering harnesses H1-H4 and H6-H8 and shuttle 1 moves from left to right to weave the fifth weft yarn 110b in layer L1. The sixth shed 160 is formed by raising harnesses H1-H2 and H5 and lowering harnesses H3-H4 and H6-H8 and shuttle 1 moves from right to left to weave the sixth weft yarn 110b in layer 2 to complete one repeat of forming the top smaller tube 322a. The seventh shed 160 is formed by raising harnesses H1-H2 and H5-H7 and lowering harnesses H3-H4 and H8 and shuttle 2 moves from left to right to weave the seventh weft yarn 110b in layer L3. The eighth shed 160 is formed by raising harness H1-H7 and H8 and lowering harness H8 and shuttle 2 moves from right to left to weave the eighth weft yarn 110b in layer 4 to complete one repeat of forming the bottom smaller tube 322b. The eight sheds 160 and 8 weft yarn 110b insertion repeat using shuttles 1 and 2 as described and continues until the desired length of leg section 310 is completed.

One skilled in the art will recognize that the sequence of weft yarn 110b insertion described above is not the only way to produce smaller tubes 322a and 322b. FIG. 10 shows a second graphical representation of one repeat (8 warp yarns 110a and 8 weft yarns 110b) of the weave design, DID (drawing-in-draft) and chain (or lift) plan on square paper for forming the two smaller tubes 322a and 322b in plain weave. The alternative sequence of weft yarn 110b insertion to form the two smaller tubes 322a and 322b shown in FIG. 10 is to weave one weft yarn 110b in layer L1 using shuttle 1, followed by weaving a weft yarn 110b in layer L3 using shuttle 2, etc.

Weave/Pattern Match

One advantage of the present invention is the weave/pattern match that is readily done when assigning weaves to each of the four layers L1-L4. As a non-limiting example, FIG. 11a shows a schematic of a top view of the unfolded pants 400 made with a 3/1 right hand (RH) twill exhibited on the shown side of the bifurcated product. To make the pants 400, weave assignments layers L1 and L3 are 3/1 RH twill and the weave assignments four layers L2 and L4 are 1/3 left hand (LH) twill. Adjustment in the number of warp yarns for the waist section 312 and the leg section 310 is done for the continuation of the weave (3/1 RH twill) on the surface (shown side) of the bifurcated structure. FIG. 11b shows a schematic of the waist section 312 of the pants shown in FIG. 11a cut along the L1, L4 interface and laid out flat, showing the continuous pattern. The darker layer rendition 402 on the right represents the fact that L2 and L4 have their hidden side facing up on the weaving machine while L1 and L3 have their shown side facing up on the weaving machine. Alternatively, L1 and L3 can have their hidden side facing up on the weaving machine while L2 and L4 have their shown side facing up on the weaving machine.

Weave/pattern match is not limited to the aforementioned weaves and can be expanded to other varied and broad weaves such as herringbones and houndstooth. It can also produce continuous patterns such as plaids and stripes. When jacquard is implemented the possibility of weave pattern designs are infinite. FIG. 12 is a schematic of a top view of the unfolded waist section 312 of pants (not shown), cut at the L1/L4 interface and laid flat. The waist section 312 was made with a floral design. The floral design is repeated continuously around the pants. As in FIG. 11b, the darker layer rendition 402 on the right represents the fact that L2 and L4 have their hidden side facing up on the weaving machine while L1 and L3 have their shown side facing up on the weaving machine. Alternatively, L1 and L3 can have their hidden side facing up on the weaving machine while L2 and L4 have their shown side facing up on the weaving machine.

In some aspects, the techniques described herein relate to a process for making a branched tubal structure, the process including weaving the branched tubal structure in at least four layers. The at least four layers are stacked on a weaving machine, and the branched tubal structure includes a first section connected to a second section. The first section includes each of the at least four layers connected in a larger tube, and the second section includes sequential pairs of the at least four layers connected in at least two smaller tubes.

In some aspects, all of the at least four layers are continuously connected in the first section and/or the second section. In some aspects, at least two of the at least four layers are not continuously connected. In some aspects, at least two layers of the at least four layers are not connected proximate an end of the first section distal to the second section. In some aspects, at least two layers of the at least four layers are not connected proximate an end of the second section distal to the first section. In some aspects, at least two of the at least four layers are not connected for a portion within the first section and/or the second section.

In some aspects, the weaving is selected from the group consisting of shuttle weaving or shuttleless weft insertion system. In some aspects, a method of the weaving is selected from the group consisting of use of at least one sectionally continuous weft yarn, or discontinuous weft yarn with use of leno selvages, use of tucked-in selvages or use of heat-sealed selvages.

In some aspects, the branched tubal structure is woven using at least one pattern selected from the group consisting of a plain weave and its derivatives; a twill weave and its derivatives; a satin/sateen weave and its derivatives; dobby; or jacquard. In some aspects, the branched tubal structure is woven in a pattern selected from the group consisting of a plain weave and its derivatives; a twill weave and its derivatives; a satin/sateen weave and its derivatives; or dobby. In some aspects, the branched tubal structure is woven using a jacquard pattern. In some aspects, the branched tubal structure is woven using a jacquard pattern and at least one pocket is added to the larger tube and/or at least one of the at least two smaller tubes.

In some aspects, the at least one pattern matches around the larger tube and/or the at least two smaller tubes.

In some aspects, the larger tube and each of the at least two smaller tubes are woven using at least 8 harnesses. In some aspects, at least 2 harnesses are dedicated to each of the at least four layers.

In some aspects, the at least four layers comprise yarn from cotton, linen, silk, wool, hemp, modal, lyocell, rayon, polyester, nylon, spandex fiber, and/or metal fibers. In some aspects, the at least four layers comprise yarn from cotton, linen, silk, wool, hemp, modal, rayon, lyocell, polyester, nylon, and/or spandex fiber. In some aspects, the at least four layers comprise a yarn containing spandex fiber.

In some aspects, the branched tubal structure comprises a piece of apparel, a medical implant, a medical device, a plumbing part, an automotive part, and/or a machine part. In some aspects, the branched tubal structure comprises a piece of apparel.

In some aspects, the first section is woven before the second section. In some aspects, the second section is woven before the first section.

In some aspects, the at least four layers of the larger tube and the sequential pairs of the at least four layers of the at least two smaller tubes are each connected by one sectionally continuous weft yarn. In some aspects, the at least four layers of the larger tube and the sequential pairs of the at least four layers of the at least two smaller tubes are each connected by use of leno selvages. In some aspects, the at least four layers of the larger tube and the sequential pairs of the at least four layers of the at least two smaller tubes are each connected by the use of tucked-in selvages. In some aspects, the at least four layers of the larger tube and the sequential pairs of the at least four layers of the at least two smaller tubes are each connected by the use of heat-sealed selvages.

In some aspects, the larger tube is woven using at least one shuttle and the at least two smaller tubes are woven using at least two shuttles.

In some aspects, the leno selvages are visible on an outside of the branched tubal structure. In some aspects, the leno selvages are not visible on the outside of the branched tubal structure.

In some aspects, thermoplastic fibers are located at each edge of each of the at least four layers, and the process further comprises: melting at least a portion of the thermoplastic fibers to form the heat-sealed selvages.

In some aspects, the techniques described herein relate to a process for making a bifurcated tubal structure. The process including: weaving the bifurcated tubal structure in four layers, wherein the four layers are stacked on a weaving machine. The bifurcated tubal structure includes a first section connected to a second section. The first section includes each of the four layers connected in a larger tube, and the second section includes sequential pairs of the four layers connected in two smaller tubes.

In some aspects, all of the four layers are continuously connected in the first section and/or the second section. In some aspects, at least two of the four layers are not continuously connected in the first section and/or the second section. In some aspects, at least two layers of the four layers are not connected proximate an end of the first section distal to the second section. In some aspects, at least two layers of the four layers are not connected proximate an end of the second section distal to the first section. In some aspects, at least two of the four layers are not connected for a portion within the first section and/or the second section.

In some aspects, the weaving is selected from the group consisting of shuttle weaving or shuttleless weft insertion system. In some aspects, a method of the weaving is selected from the group consisting of use of at least one sectionally continuous weft yarn, or use of discontinuous weft yarn with use of leno selvages, use of tucked-in selvages or use of heat-sealed selvages.

In some aspects, the bifurcated tubal structure is woven using at least one pattern selected from the group consisting of a plain weave and its derivatives; a twill weave and its derivatives; a satin/sateen weave and its derivatives; dobby; or jacquard. In some aspects, the bifurcated tubal structure is woven in a pattern selected from the group consisting of a plain weave and its derivatives; a twill weave and its derivatives; a satin/sateen weave and its derivatives; or dobby. In some aspects, the bifurcated tubal structure is woven using a jacquard pattern. In some aspects, the bifurcated tubal structure is woven using a jacquard pattern and at least one pocket is added to the larger tube and/or at least one of the two smaller tubes.

In some aspects, the at least one pattern matches around the larger tube and/or at least one of the two smaller tubes.

In some aspects, the larger tube and each of the two smaller tubes are woven using at least 8 harnesses, and at least 2 harnesses are dedicated to each of the four layers.

In some aspects, the at least four layers comprise yarn from cotton, linen, silk, wool, hemp, modal, lyocell, rayon, polyester, nylon, spandex fiber, and/or metal fiber and their blends. In some aspects, the at least four layers comprise yarn from cotton, linen, silk, wool, hemp, modal, rayon, lyocell, polyester, nylon, and/or spandex fiber. In some aspects, the at least four layers comprise a yarn containing spandex fiber.

In some aspects, the bifurcated tubal structure comprises a piece of apparel, a medical implant, a medical device, a plumbing part, an automotive part, and/or a machine part. In some aspects, the bifurcated tubal structure comprises a piece of apparel. In some aspects, the bifurcated tubal structure comprises the pants.

In some aspects, the first section is woven before the second section. In some aspects, the second section is woven before the first section.

In some aspects, the four layers of the larger tube and the sequential pairs of the four layers of the two smaller tubes are each connected by one sectionally continuous weft yarn. In some aspects, the four layers of the larger tube and the sequential pairs of the four layers of the two smaller tubes are each connected by use of leno selvages. In some aspects, the four layers of the larger tube and the sequential pairs of the four layers of the two smaller tubes are each connected by the use of tucked-in selvages. In some aspects, the four layers of the larger tube and the sequential pairs of the four layers of the two smaller tubes are each connected by the use of heat-sealed selvages.

In some aspects, the larger tube is woven using at least one shuttle and the two smaller tubes are woven using at least two shuttles.

In some aspects, the leno selvages are visible on an outside of the bifurcated tubal structure. In some aspects, the leno selvages are not visible on the outside of the bifurcated tubal structure.

In some aspects, thermoplastic fibers are located at each edge of each of the four layers, and the process further comprises: melting at least a portion of the thermoplastic fibers to form the heat-sealed selvages.

In some aspects, the techniques described herein relate to a process for making a bifurcated tubal structure, the process including: (a) setting a warp sheet including warp yarns on a weaving machine; (b) dividing the warp yarns between at least 8 harnesses, wherein four sets of warp yarns are distributed among the at least 8 harnesses, and wherein the four sets of warp yarns correspond to four layers of woven fabric, L1, L2, L3, and L4; (c) implementing a first sequence of at least 8 sheds, wherein a first weft yarn is inserted into each of the four layers in a first order that connects the four layers of woven fabric in a larger tube, and optionally implementing a modified first sequence of the at least 8 sheds, wherein the first weft yarn is inserted into each of the four layers in a modified first order that connects the four layers of woven fabric in the larger tube and wherein at least two of the four layers are not continuously connected; (d) repeating step c) until the larger tube is formed to a first desired length; (e) implementing a second sequence of at least 8 sheds, wherein a second weft yarn is inserted into each of the layers L1 and L2 and a third weft yarn is inserted into each of the layers L3 and L4, in a second order that connects the layers L1 and L2 in a first smaller tube and the layers L3 and L4 in a second smaller tube, and optionally implementing a modified second sequence of the at least 8 sheds wherein the second weft yarn is inserted into each of the layers L1 and L2 and a third weft yarn is inserted into each of the layers L3 and L4, in a modified second order that connects the layers L1 and L2 in a first smaller tube, the layers L3 and L4 in a second smaller tube, and wherein the layers L1 and L2 and/or the layers L3 and L4 are not continuously connected; and (f) repeating step e) until the first smaller tube and the second smaller tube are a second desired length. The larger tube is folded while on the weaving machine, and the first smaller tube and the second smaller tube are staked while on the weaving machine. A movement of the at least 8 harnesses in step c) is set by the first sequence of the at least 8 sheds and optionally the modified first sequence of the at least 8 sheds, and the movement of the at least 8 harnesses in step e) is set by the second sequence of at least 8 sheds and optionally by the modified second sequence of the at least 8 sheds. The larger tube is connected to the first smaller tube and the second smaller tube.

In some aspects, steps e) through f) are performed before steps c) through d).

In some aspects, the modified first sequence is implemented in step c) and/or the modified second sequence is implemented in step e). In some aspects, the modified first sequence is implemented in step c). In some aspects, the modified second sequence is implemented in step e).

In some aspects, the second weft yarn is a continuation of the first weft yarn. In some aspects, the third weft yarn is a continuation of the first weft yarn.

In some aspects, the bifurcated tubal structure is woven using at least one pattern selected from the group consisting of a plain weave and its derivatives; a twill weave and its derivatives; a satin/sateen weave and its derivatives; dobby; or jacquard. In some aspects, the bifurcated tubal structure is woven in a pattern selected from the group consisting of a plain weave and its derivatives; a twill weave and its derivatives; a satin/sateen weave and its derivatives; and/or dobby. In some aspects, the bifurcated tubal structure is woven using a jacquard pattern. In some aspects, the bifurcated tubal structure is woven using a jacquard pattern and at least one pocket is added to the larger tube, the first smaller tube, and/or the second smaller tube.

In some aspects, the at least one pattern matches around the larger tube, the first smaller tube, and/or the second smaller tube.

In some aspects, the at least four layers comprise yarn from cotton, linen, silk, wool, hemp, modal, lyocell, rayon, polyester, nylon, spandex fiber, and/or metal fiber. In some aspects, the at least four layers comprise yarn from cotton, linen, silk, wool, hemp, modal, rayon, lyocell, polyester, nylon, and/or spandex fiber. In some aspects, the at least four layers comprise a yarn containing spandex fiber.

In some aspects, the bifurcated tubal structure forms a piece of apparel, a medical implant, a medical device, a plumbing part, an automotive part, and/or a machine part. In some aspects, the bifurcated tubal structure forms a piece of apparel. In some aspects, the bifurcated tubal structure forms pants.

In some aspects, at least one first shuttle is used to insert the first weft yarn in step c), and at least one second shuttle is used to insert the second weft yarn and at least one third shuttle is used to insert the third weft yarn in step e).

In some aspects, the first weft yarn and the second weft yarn are continuous, or the first weft yarn and the third weft yarn are continuous.

Clause 1. A process for making a branched tubal structure, the process comprising weaving the branched tubal structure in at least four layers, wherein the at least four layers are stacked on a weaving machine, wherein the branched tubal structure comprises a first section connected to a second section, wherein the first section comprises each of the at least four layers connected in a larger tube, and wherein the second section comprises sequential pairs of the at least four layers connected in at least two smaller tubes.

Clause 2. The process of clause 1, wherein all of the at least four layers are continuously connected in the first section and/or the second section; or wherein at least two of the at least four layers are not continuously connected; or wherein at least two layers of the at least four layers are not connected proximate an end of the first section distal to the second section; or wherein at least two layers of the at least four layers are not connected proximate an end of the second section distal to the first section; or wherein at least two of the at least four layers are not connected for a portion within the first section and/or the second section.

Clause 3. The process of any one of clauses 1 or 2, wherein the weaving is selected from the group consisting of shuttle weaving or shuttleless weft insertion system; or wherein a method of the weaving is selected from the group consisting of use of at least one sectionally continuous weft yarn, or discontinuous weft yarn with use of leno selvages, use of tucked-in selvages or use of heat-sealed selvages.

Clause 4. The process of any one of clauses 1-3, wherein the branched tubal structure is woven using at least one pattern selected from the group consisting of a plain weave and its derivatives; a twill weave and its derivatives; a satin/sateen weave and its derivatives; dobby; or jacquard; or wherein the branched tubal structure is woven in a pattern selected from the group consisting of a plain weave and its derivatives; a twill weave and its derivatives; a satin/sateen weave and its derivatives; or dobby; or wherein the branched tubal structure is woven using a jacquard pattern; or wherein the branched tubal structure is woven using a jacquard pattern and at least one pocket is added to the larger tube and/or at least one of the at least two smaller tubes.

Clause 5. The process of clause 4, wherein the at least one pattern matches around the larger tube and/or the at least two smaller tubes.

Clause 6. The process of any one of clauses 1-5, wherein the larger tube and each of the at least two smaller tubes are woven using at least 8 harnesses, and wherein at least 2 harnesses are dedicated to each of the at least four layers.

Clause 7. The process of any one of clauses 1-6, wherein the at least four layers comprise yarn from cotton, linen, silk, wool, hemp, modal, lyocell, rayon, polyester, nylon, spandex fiber, and/or metal fiber; or wherein the at least four layers comprise yarn from cotton, linen, silk, wool, hemp, modal, rayon, lyocell, polyester, nylon, and/or spandex fiber.

Clause 8. The process of any one of clauses 1-7, wherein the branched tubal structure comprises a piece of apparel, a medical implant, a medical device, a plumbing part, an automotive part, and/or a machine part. In some aspects, the bifurcated tubal structure forms a piece of apparel. In some aspects, the bifurcated tubal structure forms pants.

Clause 9. The process of any one of clauses 1-8, wherein the first section is woven before the second section; or wherein the second section is woven before the first section.

Clause 10. The process of any one of clauses 1-9, wherein the at least four layers of the larger tube and the sequential pairs of the at least four layers of the at least two smaller tubes are each connected by one sectionally continuous weft yarn; or wherein the at least four layers of the larger tube and the sequential pairs of the at least four layers of the at least two smaller tubes are each connected by use of leno selvages; or wherein the at least four layers of the larger tube and the sequential pairs of the at least four layers of the at least two smaller tubes are each connected by the use of tucked-in selvages; or wherein the at least four layers of the larger tube and the sequential pairs of the at least four layers of the at least two smaller tubes are each connected by the use of heat-sealed selvages.

Clause 11. The process of clause 10, wherein the larger tube is woven using at least one shuttle and the at least two smaller tubes are woven using at least two shuttles.

Clause 12. The process of clause 10, wherein the leno selvages are visible on an outside of the branched tubal structure; or wherein the leno selvages are not visible on the outside of the branched tubal structure.

Clause 13. The process of clause 10, wherein thermoplastic fibers are located at each edge of each of the at least four layers, and wherein the process further comprises: melting at least a portion of the thermoplastic fibers to form the heat-sealed selvages.

Clause 14. A process for making a bifurcated tubal structure, the process comprising: weaving the bifurcated tubal structure in four layers, wherein the four layers are stacked on a weaving machine, wherein the bifurcated tubal structure comprises a first section connected to a second section, wherein the first section comprises each of the four layers connected in a larger tube, and wherein the second section comprises sequential pairs of the four layers connected in two smaller tubes.

Clause 15. The process of clause 14, wherein all of the four layers are continuously connected in the first section and/or the second section; or wherein at least two of the four layers are not continuously connected in the first section and/or the second section; or wherein at least two layers of the four layers are not connected proximate an end of the first section distal to the second section; or wherein at least two layers of the four layers are not connected proximate an end of the second section distal to the first section; or wherein at least two of the four layers are not connected for a portion within the first section and/or the second section.

Clause 16. The process of any one of clauses 14 or 15, wherein the weaving is selected from the group consisting of shuttle weaving or shuttleless weft insertion system; or wherein a method of the weaving is selected from the group consisting of use of at least one sectionally continuous weft yarn, or use of discontinuous weft yarn with use of leno selvages, use of tucked-in selvages or use of heat-sealed selvages.

Clause 17. The process of any one of clauses 14-16, wherein the bifurcated tubal structure is woven using at least one pattern selected from the group consisting of a plain weave and its derivatives; a twill weave and its derivatives; a satin/sateen weave and its derivatives; dobby; or jacquard; or wherein the bifurcated tubal structure is woven in a pattern selected from the group consisting of a plain weave and its derivatives; a twill weave and its derivatives; a satin/sateen weave and its derivatives; or dobby; or wherein the bifurcated tubal structure is woven using a jacquard pattern; or wherein the bifurcated tubal structure is woven using a jacquard pattern and at least one pocket is added to the larger tube and/or at least one of the two smaller tubes.

Clause 18. The process of clause 17, wherein the at least one pattern matches around the larger tube and/or at least one of the two smaller tubes.

Clause 19. The process of any one of clauses 14-18, wherein the larger tube and each of the two smaller tubes are woven using at least 8 harnesses, and wherein at least 2 harnesses are dedicated to each of the four layers.

Clause 20. The process of any one of clauses 14-19, wherein the four layers comprise yarn from cotton, linen, silk, wool, hemp, modal, lyocell, rayon, polyester, nylon, spandex fiber, and/or metal fiber; or wherein the four layers comprise yarn from cotton, linen, silk, wool, hemp, modal, rayon, lyocell, polyester, nylon, and/or spandex fiber.

Clause 21. The process of any one of clauses 14-20, wherein the bifurcated tubal structure comprises a piece of apparel, a medical implant, a medical device, a plumbing part, an automotive part, and/or a machine part; or wherein the bifurcated tubal structure comprises a piece of apparel; or wherein the bifurcated tubal structure comprises pants.

Clause 22. The process of any one of clauses 14-21, wherein the first section is woven before the second section; or wherein the second section is woven before the first section.

Clause 23. The process of any one of clauses 14-22, wherein the four layers of the larger tube and the sequential pairs of the four layers of the two smaller tubes are each connected by one sectionally continuous weft yarn; or wherein the four layers of the larger tube and the sequential pairs of the four layers of the two smaller tubes are each connected by use of leno selvages; or wherein the four layers of the larger tube and the sequential pairs of the four layers of the two smaller tubes are each connected by the use of tucked-in selvages; or wherein the four layers of the larger tube and the sequential pairs of the four layers of the two smaller tubes are each connected by the use of heat-sealed selvages.

Clause 24. The process of clause 23, wherein the larger tube is woven using at least one shuttle and the two smaller tubes are woven using at least two shuttles.

Clause 25. The process of clause 23, wherein the leno selvages are visible on an outside of the bifurcated tubal structure; or wherein the leno selvages are not visible on the outside of the bifurcated tubal structure.

Clause 26. The process of clause 23, wherein thermoplastic fibers are located at each edge of each of the four layers, and wherein the process further comprises: melting at least a portion of the thermoplastic fibers to form the heat-sealed selvages.

Clause 27. A process for making a bifurcated tubal structure, the process comprising: (a) setting a warp sheet comprising warp yarns on a weaving machine; (b) dividing the warp yarns between at least 8 harnesses, wherein four sets of warp yarns are distributed among the at least 8 harnesses, and wherein the four sets of warp yarns correspond to four layers of woven fabric, L1, L2, L3, and L4; (c) implementing a first sequence of at least 8 sheds, wherein a first weft yarn is inserted into each of the four layers in a first order that connects the four layers of woven fabric in a larger tube, and optionally implementing a modified first sequence of the at least 8 sheds, wherein the first weft yarn is inserted into each of the four layers in a modified first order that connects the four layers of woven fabric in the larger tube and wherein at least two of the four layers are not continuously connected; (d) repeating step c) until the larger tube is formed to a first desired length; (e) implementing a second sequence of at least 8 sheds, wherein a second weft yarn is inserted into each of the layers L1 and L2 and a third weft yarn is inserted into each of the layers L3 and L4, in a second order that connects the layers L1 and L2 in a first smaller tube and the layers L3 and L4 in a second smaller tube, and optionally implementing a modified second sequence of the at least 8 sheds wherein the second weft yarn is inserted into each of the layers L1 and L2 and a third weft yarn is inserted into each of the layers L3 and L4, in a modified second order that connects the layers L1 and L2 in a first smaller tube, the layers L3 and L4 in a second smaller tube, and wherein the layers L1 and L2 and/or the layers L3 and L4 are not continuously connected; and (f) repeating step e) until the first smaller tube and the second smaller tube are a second desired length, wherein the larger tube is folded while on the weaving machine, wherein the first smaller tube and the second smaller tube are stacked while on the weaving machine, wherein a movement of the at least 8 harnesses in step c) is set by the first sequence of the at least 8 sheds and optionally the modified first sequence of the at least 8 sheds, and the movement of the at least 8 harnesses in step e) is set by the second sequence of at least 8 sheds and optionally by the modified second sequence of the at least 8 sheds, and wherein the larger tube is connected to the first smaller tube and the second smaller tube.

Clause 28. The process of clause 27, wherein steps e) through f) are performed before steps c) through d).

Clause 29. The process of any one of clauses 27 or 28, wherein the modified first sequence is implemented in step c) and/or the modified second sequence is implemented in step e); or wherein the modified first sequence is implemented in step c); or wherein the modified second sequence is implemented in step e).

Clause 30. The process of any one of clauses 27-29, wherein the second weft yarn is a continuation of the first weft yarn; or wherein the third weft yarn is a continuation of the first weft yarn.

Clause 31. The process of any one of clauses 27-30, wherein the bifurcated tubal structure is woven using at least one pattern selected from the group consisting of a plain weave and its derivatives; a twill weave and its derivatives; a satin/sateen weave and its derivatives; dobby; or jacquard; or wherein the bifurcated tubal structure is woven in a pattern selected from the group consisting of a plain weave and its derivatives; a twill weave and its derivatives; a satin/sateen weave and its derivatives; and/or dobby; or wherein the bifurcated tubal structure is woven using a jacquard pattern; or wherein the bifurcated tubal structure is woven using a jacquard pattern and at least one pocket is added to the larger tube, the first smaller tube, and/or the second smaller tube.

Clause 32. The process of clause 31, wherein the at least one pattern matches around the larger tube, the first smaller tube, and/or the second smaller tube.

Clause 33. The process of any one of clauses 27-32, wherein the warp yarns, the first weft yarn, the second weft yarn, and the third weft yarn comprises cotton, linen, silk, wool, hemp, modal, lyocell, rayon, polyester, nylon, spandex fiber, and/or metal fiber; or wherein the warp yarns, the first weft yarn, the second weft yarn, and the third weft yarn comprise cotton, linen, silk, wool, hemp, modal, lyocell, rayon, polyester, nylon, and/or spandex fiber.

Clause 34. The process of any one of clauses 27-33, wherein the bifurcated tubal structure forms a piece of apparel, a medical implant, a medical device, a plumbing part, an automotive part, and/or a machine part; or wherein the bifurcated tubal structure forms a piece of apparel; or wherein the bifurcated tubal structure forms pants.

Clause 35. The process of any one of clauses 27-33, wherein at least one first shuttle is used to insert the first weft yarn in step c), and wherein at least one second shuttle is used to insert the second weft yarn and at least one third shuttle is used to insert the third weft yarn in step e).

Clause 36. The process of clause 35, wherein the first weft yarn and the second weft yarn are continuous or wherein the first weft yarn and the third weft yarn are continuous.

EXAMPLES

Prototypes were produced to show the viability of the weaving process on both dobby weaving machines and on jacquard weaving machines.

Example 1

FIG. 13 is a front view of prototype pants 450 that were produced on an AVL dobby weaving machine (loom) in manual mode. The weaving machine (loom) was set up with 16 harnesses, hand shuttle insertion and a plain weave to form the bifurcated structure in folded form. There were 32 EPI/4 layers (i.e., 8 EPI per layer), an 8 DPI reed sleyed 4 ends per dent, where EPI is ends per inch and DPI is reed dents per inch. The warp sheet was 12 inches wide, and the warp and weft yarns were each made of 8/2 yarn count. FIG. 6 shows one repeat (8 warp yarns and 8 weft yarns) of the weave design, DID (drawing-in-draft) and chain (or lift) plan on square paper for forming four layers in plain weave. One shuttle was used for the waist section 312, and two shuttles were used for the leg section 310. This configuration was used to produce the initial prototype, proving that combining multi-layer weave designs can produce a seamless bifurcated garment.

Example 2

FIG. 14 is a back view of prototype pants 460 that were produced on a Thread Controller 2 (TC2) jacquard weaving machine (loom). The TC2 had 2640 heddles with individual control. Hand shuttle insertion was used. The warp sheet had 180 EPI/4 layers (i.e., 45 EPI per layer), a 30 DPI reed sleyed 6 ends per dent. The warp sheet was 14 and ⅔ inch wide, and the warp yarns were of count 40/2 mercerized cotton. The weft yarns used were yarn count 10/2 cotton and Sorona® (an innovative form of polyester). The TC2 made prototype illustrates the expansive design capabilities a jacquard system introduces, and how incorporating Sorona®, the biobased spandex substitute, presents shaping and sizing capabilities. When the prototype pants 460 were laid on their side, the waist edge 314 measured approximately 7 inches and the leg section 310 measured approximately 12 inches.

Example 3

A woven structure of waist section 312 and leg section 310 were produced on an AVL industrial dobby loom (IDL) in automatic mode. The loom was set up with 24 harnesses, automatic shuttle insertion to produce a 4 layer plain weave. There were 64 EPI/4 layers (i.e., 16 EPI per layer), a 16 DPI reed sleyed 4 ends per dent. The warp sheet was 12 inches wide, and the warp yarn was 8/2 yarn count (half black and half white with 1 black and 1 white sequence). The weft yarn was of yarn counts of 8/2 cotton, 8/4 cotton, 5/2 cotton and 3/2 cotton. The samples woven on the AVL Industrial Dobby Loom (IDL) demonstrated that the process used to develop the initial proof of concept and prototype can be automated with traditional industrial weaving machines.

Example 4

A prototype showing that an opening for closures could be created with a finished edge was woven on AVL Industrial Dobby Loom (IDL). The loom was set up with 12 harnesses and a warp with 120 EPI/4 layers (i.e., 30 EPI per layer). The yarn count of the warp was 20/2 cotton and the weft was 5/2 cotton. To form the folded four layers with edge opening, the sequence of weft insertion into each layer is as follows: L3, L4, L1, L2, L2, L1, L4, L3. This 8 weft insertion sequence is repeated until the desired opening length is reached.

FIG. 15 is a front view of a prototype pants 470 made with an opening starting at the front-center of waist edge 314. FIGS. 16a-16c show a cross-section views at the waist line 314 of tube 474 which shows the opening between L2 and L3, a cross-section view at the waist section tube 320 below the opening between L2 and L3, and a cross-section view in the leg section 310 of the prototype pants 470 folded on the weaving machine (not shown). FIG. 16b and FIG. 16c are identical to FIG. 5b and FIG. 5c, respectively. FIG. 16a shows the tube 474 with the opening finished edges 472a and 472b.

Example 5

A pocket sample woven on a commercial rapier (shuttleless) jacquard. The machine was set up with 84 EPI and a yarn count of 40/2 cotton. The weft had a yarn count of 18/2 cotton. The warp intersects between 4 and 2 layers to form this pocket: 84 EPI/4 layers (i.e., 21 EPI per layer) and 84 EPI/2 layers (i.e., 42 EPI per layer). The weft insertion sequence into each of the 6 layers (4+2) to form the pocket is as follows: L1, L4, L3, L2, L1, L4, L5, L6. This sequence of 8 weft insertions is repeated until the desired pocket length is repeated.

FIG. 17a is a front perspective view of a prototype pocket 480 made with an opening 482 starting at the waist edge 314. The outline 484 of pocket 480 can be seen as U-shaped. FIG. 17b is a cross-section view of the waist section 312 in the area where the pocket 480 was produced as a modified folded tube 486 with six layers. FIG. 17b depicts layers L2 and L3 being divided to create layers L6 and L5, respectively, to make one pocket between layers L2 and L6 and another pocket between layers L3 and L5.

In the Examples 1-5 a continuous weft yarn was used to form the folded singular tube (i.e., the waist section) and two continuous weft yarns were used to form the first and second tubes (i.e., the legs) on top of one another using shuttle weaving. Other ways to form the tubes include the use of leno selvages, use of tucked-in selvages, or use of heat-sealed selvages in case of using shuttleless weaving as the weft yarn is cut after each insertion.

Although the present invention has been illustrated and described herein with reference to preferred embodiments and specific examples thereof, it will be readily apparent to those of ordinary skill in the art that other embodiments and examples may perform similar functions and/or achieve like results. All such equivalent embodiments and examples are within the spirit and scope of the present invention and are intended to be covered by the following claims.