TECHNICAL FIELD
[0001] This invention relates to a three-dimensional multilayer woven fabric comprising
at least two layers extending substantially parallel to each other. The invention
also relates to a method for producing a multilayer woven fabric.
BACKGROUND ART
[0002] It is previously known to use stuffing within upholstery industry, where upholstery
may refer to the work of providing furniture, especially seats, with padding, springs,
webbing and fabric covers. In addition, an upholsterer may apply to domestic furniture
as well as to applications in automobiles and boats. Various procedures of producing
upholstery apply to various fields. For instance, when designing seats for automobiles
a supporting metal frame, virtually corresponding to the shape of the seat, is covered
with an injection molded foam, usually made out of polyurethane. The layer of polyurethane
is then draped with an additional cover of composite fabric which generally consists
of a lower base material, a middle layer of foam padding (made out of polyurethane)
and an outer cover of thin tricot fabric. Said composite fabric is put together by
means of lamination or gluing; a procedure which is quite laborious as well as time
consuming.
[0003] Also, having a substantial portion made of polyurethane the foam material within
these composite fabrics cannot be recycled. An example of such laminated material
is presented in
US 2005/0214511.
[0004] Another type of material is shown in patent
US 4,379,798 wherein is shown a three-dimensional integral woven reinforcement for structural
components which are applicable within airplanes, ships and automobiles. The material
in
US 4,379,798 is formed as an integral woven assembly of warp and fill yarns, with tie yarn passing
from one side of the layer to the other. The fabric is arranged in a certain shape
whereupon it is impregnated with resin in order to form the desired structural component.
A material according to
US 4,379,798 would not be suitable as upholstery fabric since its quality is robust and primarily
adapted to act as a spacer that is rigid and has a fixated structure.
[0005] EP 1 568 808 describes still another three-dimensional woven fabric comprising a surface layer
having a woven structure, a back layer having a woven structure and a bonding layer
having a woven structure and corrugated in a wave-like shape in the warp or weft direction.
The three dimensional structure is created by means of a high temperature shrinkage
procedure following the production of the actual fabric. This limits the choice of
material considerably, allowing employment of exclusively yarn with "high shrinkage
property with respect to heat".
[0006] Another multilayer material is described in
DE 94 19 009 U1. The textile described therein comprises two middle layers arranged in opposite direction
relative to each other and integrated by crossing each other between the outer layers.
At the position where the two middle layers cross each other (i.e. are integrated),
a structure which counteracts and reduces resiliency upon compression will inevitably
be created. Moreover, the two middle layers are arranged to meet the outer layers
at an angle and create elongated cavities throughout the textile structure.
[0007] An increasingly important area within the field of material science concerns the
development of smart textiles, meaning fabrics that assume additional function/s over
the conventional purpose. For instance by integrating conductive filaments a material
may be heatable and/or could be provided with a function of e.g. sensing humidity
or measuring temperature. A known problem within this technical field is how to protect
the conductive parts within the fabric (or any functional filament) from outer wear
and tear that would disturb or even harm the function.
DISCLOSURE OF THE INVENTION
[0008] It is an object of the present invention to solve or at least to minimise the above
mentioned problems. This is achieved by means of a three-dimensional multilayer woven
fabric comprising at least two woven layers extending substantially parallel to each
other wherein said woven fabric further comprises a woven interconnecting support
structure interposed between the at least two layers and being arranged to connect
the at least two layers with each other, wherein said interconnecting support structure
comprises one single layer of warp yarn and weft yarn, wherein said warp yarn is arranged
to be integrated with and extend between, and substantially perpendicular against,
the planes defined by said upper and lower adjacent two layers in an alternating manner
thus forming a single undulating structure, and wherein said warp yarn in the interconnecting
support structure is made of a resilient material, so that said interconnecting support
structure will return to its original shape after having been compressed. The interconnecting
structure may also be referred to as an "interconnecting middle layer", "interconnecting
layer" or "intermediate layer".
[0009] The interconnecting layer comprises a plurality of distancing layers each whereof
is extending between the at least two adjacent layers, and wherein said distancing
layers are arranged to distance the two adjacent layers from each other. Further said
distancing layers comprises warp yarn extending substantially perpendicularly to the
planes defined by the adjacent at least two layers.
[0010] When producing the fabric according to the invention the at least two layers and
the interconnecting middle layer are woven simultaneously in one step, meaning a multiple
layer fabric is acquired directly from the loom.
[0011] Several advantages are achieved thanks to the inventive multiple layer fabric, which
comprises at least two layers (a first upper and a second lower layer) connected and
stabilized by an intermediate interconnecting structure. According to one example
of the invention the interconnecting structure represents a middle supporting layer
within the fabric which stabilizes two adjacent outer layers, and at the same time
keeps the fabric flexible and soft. Hereby the multilayer fabric is perfectly suitable
e.g. as upholstery material e.g. for furniture, car seats and/or mattresses, and could
thus readily replace any conventional laminated composite material.
[0012] Being woven in one step a multilayer fabric may be collected directly from the loom
and brought to e.g. an upholster and/or other manufacturers, virtually without any
need of other ensuing treatments prior to further use. In particular, laborious lamination
and/or gluing procedures are excluded from the making of the fabric which saves working
time and cuts the cost of making upholstery material.
[0013] Moreover, the materials that are chosen for weaving the fabric according to the invention
are preferably recyclable, meaning that the material provides an environmental friendly
alternative to present composite fabrics.
[0014] Another advantage brought by the inventive fabric is that the woven material will
provide outer layers which are rigid and wear resistant, and at the same time may
provide a dense and smooth surface, which is a required property in particular for
materials that are meant to form a sitting area of e.g. a couch, an armchair or a
car seat.
[0015] In addition, each or all of the many layers may comprise yarn that provides a certain
utility, e.g. yarn that is conductive, which would lead to a fabric that is associated
with a function. If, for instance, such a conductive yarn would be integrated within
the middle layer of the fabric according to the invention, these yarns are shielded
from outer wear which helps to avoid short circuits and/or prolongs the lifetime of
the functionality of the smart textile in question.
[0016] Each of the at least three layers (e.g. the upper, middle and lower layers) in the
fabric according to the invention is woven independently, but simultaneously, in a
weaving machine, meaning that for instance the quality of the yarn as well as the
thickness and design of the respective upper, intermediate and lower layer may be
chosen individually. The upper side surface design and the lower side surface design
of the multilayer fabric may be composed out of two designs different from each other.
This leads to a large number of possible variations of fabric design and quality which
enables for adaption thereof to particular needs. For instance, if the multiple layer
fabric is supposed to cover an office chair the layer of the fabric which will be
facing outwards may be woven with a certain pattern, in a specific colour or in a
quality that for instance is made particularly smooth and soft, in order to render
a comfortable seat. At the same time, thanks to the inventive weaving method, the
innermost layer of the fabric could be woven in a less expensive material and/or be
more/less rigid compared to the outermost layer.
[0017] Another area of application of the multiple layer fabric is in the field of interior
architecture, especially due to a capacity of absorbing sound waves. As a result of
the many layers the fabric can be designed to dampen sounds, for instance by providing
the intermediate layer with a bulky yarn type, which makes it suitable to act as wall
and/or ceiling cover. Furthermore, the outer layers of the fabric may be designed
and patterned an any way possible within a weaving process. Thus, the fabric would
be suitable to for instance partially drape walls and ceilings within a room, thereby
providing decorative details and at the same achieve a less noisy environment since
the fabric will readily absorb parts of emitted sound waves.
[0018] It is possible to create a multilayer fabric according to the invention with more
than three layers, as previously described. In such an arrangement said three-dimensional
multilayer woven fabric may for instance comprise three layers extending substantially
parallel in such a way representing one upper, one middle and one lower layer, said
upper and middle layers representing one pair, and said middle and lower layers representing
another pair, wherein each pair of parallel layers is connected by an interconnecting
structure in the form of an interconnecting layer. Each of the two interconnecting
layers in the given example, in their turn, is arranged to undulate between, and be
integrated with, one of said pair of layers during the weaving process, thus forming
a plurality of distancing layers. Said three layers and said two interconnecting layers
of the present example are woven simultaneously in a loom during the manufacturing
process, creating a fabric with five layers, each layer which may be designed individually
from the other ones, and still the whole entity is manufactured in one single manufacturing
procedure.
[0019] The five layers as referred to in the above given example would be: a first upper
layer, a second interconnecting layer, a third mid-layer, a fourth interconnecting
layer and a fifth lower layer. Such a fabric may be used e.g. as a functional material,
where conductive threads may be integrated within one of the inner layers (i.e. within
either of the interconnecting layers, or within the third mid-layer) which means conductive
threads are protected from outer wear and tear at least by the uppermost and lowermost
layers.
[0020] It is understood that by "yarn" means any kind of yarn, thread or other suitable
filament or fiber that may be used for weaving. Yarns to be chosen in the present
invention may be selected depending on the using purpose. Examples of suitable yarns
include, in addition to monofilaments, multifilaments, spun yarns, bulky yarn or stretchy
yarn. The material of the warp and weft yarns used in said layers of the fabric can
be selected freely and usable examples include polyester, nylon, cotton, wool and
metal.
[0021] According to yet another aspect of the invention each of said interconnecting layers
consists of a continuous woven layer arranged to be folded back and forth between
two adjacent layers by means of weaving. Hereby the interconnecting middle layer will
be arranged to undulate (i.e. it will have a wavelike form) in between the adjacent
upper and lower layers.
[0022] The interconnecting structure, in the form of an undulate layer, comprises warp yarn
and preferably also weft yarn, meaning it is a woven material where the weaving takes
place simultaneously to weaving the other layers that constitute the fabric.
It is understood that "undulate" said continuous layer refers to that the woven intermediate
layer is brought to be alternately attached to, and by means of weaving integrated
with, the upper and the lower layers respectively during the process of weaving.
[0023] Preferably, the material of the warp yarns used in said interconnecting structure
is a resilient material, such as polyester or nylon.
[0024] The material of the weft yarns used in said interconnecting layer can be selected
freely depending on the purpose of use. Examples of appropriate materials for weft
yarns in said interconnecting layer may include metal, optic fiber, polyester, cotton,
wool and other manmade materials such as polyvinylidene fluoride, polypropylene sulfide,
polyethylene naphtalate.
[0025] During weaving, the warp of the middle interconnecting layer will alternate between,
firstly, attaching to the adjacent upper layer and, secondly, attaching to the adjacent
lower layer of the fabric hereby forming an undulatory structure. This results in
a number of interconnecting bridges from one layer to the other, also called distancing
layers. The resilient property of the warp within said interconnecting bridges will
give the structure both a supporting and a stabilizing function, but will also at
the same time allow a certain softness to the material.
[0026] The intermediate interconnecting structure and its distancing layers will be substantially
covered by the adjacent layers of the fabric. In particular the weft of the intermediate
layer will be completely protected from the outer surroundings, which is especially
advantageous for certain types of yarns that might be sensitive to touch and wear.
An example would be conductive filaments or conductive materials that may be integrated
within the fabric creating a system which provides the function of a sensor. A sensor
function may be e.g. to heat the material, register pressure, humidity or temperature.
If such functional filaments would be introduced as a weft within the interconnecting
layer, these filaments would be completely and effectively protected from the outside
by the surrounding layers of the fabric.
[0027] According to yet another aspect of the invention, said fabric may be designed to
comprise a particularly high absorption factor. It is understood that "absorption
factor" refers to the quality of being absorptive, meaning the capability of absorbing
e.g. a sound wave. By creating an interconnecting structure which comprises bulky
weft yarns an intermediate layer with a high absorption factor is provided. Preferably,
said multilayer fabric will provide an absorption factor between 0,4 - 0,8 for 500
Hz, and between 0,7 - 1,1 for 1 - 5 kHz.
[0028] It is understood that a multiple layer fabric may comprise one or more than one interconnecting
layer, which interconnecting layer/layers may connect one or several pairs of layers,
and where each interconnecting layer may or may not comprise functional filaments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] The fabric and method of weaving the same will hereinafter be described in more detail
with reference to the appended figures. The following description should be considered
as preferred form only, and is not decisive in a limiting sense.
- Fig. 1a
- is a perspective view showing a piece of multiple layer fabric according to one example
of the invention;
- Fig. 1b
- is a detailed view according to Ib of Fig. 1a;
- Fig. 1c
- schematically shows a portion of a side of the multiple layer fabric according to
one embodiment of the invention;
- Fig. 1d
- schematically shows a portion of a side of the multiple layer fabric according to
another embodiment of the invention;
- Fig. 2a
- is part of a cross sectional view taken somewhere along the line IIa of fig. 1;
- Fig. 2b-2c
- each shows a part of a cross section of another example of the multiple layer fabric;
- Fig. 2d
- shows part of a cross section of another example of the multiple layer fabric;
- Fig. 3a
- is part of a cross sectional view taken somewhere along the line IIIa of fig. 1;
- Fig. 3b-c
- each is a part of a cross section of the fabric according to another example of the
invention;
- Fig. 3d
- shows part of a cross sectional view taken along the line IIId of fig. 2d;
- Fig. 4
- is an example of a design diagram showing a repeating unit a multiple layer fabric
according to the present invention;
- Fig. 5a and 5b
- include cross sectional views taken along lines Va-Vd at weft 1'-4' over warp 1-16
illustrated in fig. 4 respectively;
- Fig. 6a and 6b
- includes cross sectional views taken along lines VIa-VId at warp 13-16 over weft 1'-42'
illustrated in fig. 4 respectively; and
- Fig. 7a and 7b
- is an example of how a system of warp yarns may be organized in a fabric according
to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0030] Fig. 1 schematically shows an example of a piece of multiple layer fabric 1 according
to the invention where said piece comprises an uppermost surface 13, a lowermost surface
14, a short side 2 and a long side 3 where the short side 2 represents the side that
is determined by the width of the loom wherein the fabric is produced, and the long
side 3 represents the longitudinal side which elongates out from the loom as the weaving
proceeds.
[0031] Further, the fabric according to the example of fig. 1 comprises two layers that
extend substantially parallel to each other: one upper layer 10 and one lower layer
11.
Each of said layers 10, 11 within the three-dimensional multilayer woven fabric 1
comprises warp yarns and weft yarns directed along a first and a second direction
respectively which first and second directions are substantially perpendicular to
one another in accordance with a conventional woven fabric.
[0032] The upper 10 and the lower 11 layers are interconnected by a middle intermediate
structure 12 which is arranged to zigzag between the upper 10 and lower 11 layers
thus forming a plurality of distancing layers 121 each extending between the two layers
10, 11. As is seen at the long side 3 of the piece of fabric in fig. 1, and as will
be more thoroughly explained in connection to further figures 2a-2d, the interconnecting
structure 12 is in the form of a woven continuous layer that is attached to, and directed
back and forth between, the two adjacent upper 10 and lower 12 layers of the fabric
1 thus forming an undulatory structure.
[0033] Said interconnecting structure 12 of said woven fabric contains warp yarns 122 extending
substantially along a direction substantially perpendicular to the planes defined
by said upper and lower adjacent two layers 10, 11. Thus, the warp yarns 122 of the
interconnecting structure 12 are extending in such a way crossing the planes that
are defined by each of the adjacent at least two layers 10, 11, and ties the at least
first 10 and the second 11 layers together.
[0034] The attaching of the intermediate interconnecting layer 12 to the adjacent layers
is carried out during the weaving procedure, wherein the interconnecting layer 12
is woven simultaneously with the upper 10 and the lower 11 layers. The warp of the
woven interconnecting layer is alternatingly integrated with the warp of the upper
10 and the lower 11 layer respectively, preferably forming distancing bridges 121
in between the two. Said resulting bridges 121 (also referred to as distancing layers)
are extending between the upper 10 and the lower layers 11, however, it is to be understood
that the plurality of distancing layers 121 are all part of a continuous layer preferably
consisting of warp and weft.
[0035] It is equally possible to let the intermediate layer 12 alternate between being an
integrated part of the upper 10 and the lower 11 layers without forming any distancing
bridges there between, in which example of the invention the upper 10 and the lower
11 layers are arranged closely connected parallel to each other and attached by the
intermediate layer 12.
[0036] The encircled enlargement Fig. 1B of a corner piece of fabric 1 in fig.1 shows that
the interconnecting layer 12 is connecting the upper 10 and the lower 11 layers to
each other, at the same time represents a plurality of distancing layers 121. Furthermore,
the figure shows that the interconnecting layer 12 in the given example comprises
warp 122 and weft 123 yarns. The weft yarns 123 of the intermediate layer 12 are protected
by the upper 10 and the lower 11 surfaces respectively.
[0037] The warp 122 of said intermediate layer 12 is preferably composed by a manmade material,
such as polyester threads, or any other resilient material which will provide stability
and yet allow a certain springiness to the fabric. It is understood that by "springiness"
means that the fabric will return to its original shape after having been compressed.
[0038] The general principle of weaving according to the invention is illustrated in the
schematic Figures. 1c-d, wherein is shown an example of how a warp yarn 122 of the
interconnecting middle layer 12 is arranged in relation to the adjacent upper 10 and
lower 11 layers respectively. In the figure is shown, in cross section, the weft yarns
100 of the upper layer 10 and weft yarns 110 of the lower layer 11 respectively. For
clarifying reasons no warp yarns of the upper and lower layers 10, 11 are shown. Further,
in a longitudinal section, there is shown a warp yarn 122 pertaining to the interconnecting
middle layer 12 alternating between attaching to the adjacent upper 10 and lower 11
layers respectively thus forming an undulatory structure in a longitudinal direction.
As is clear from looking at Figs. 1c-d the warp 122 of the middle layer 12 is arranged
to attach to the adjacent layers by means of binding to the weft yarns 100, 110 of
the adjacent layers 10, 11 in an alternating manner.
[0039] Also shown in cross section are weft yarns 123 of the interconnecting middle layer
12. The interconnecting middle layer 12 separates the outer adjacent layers 10, 11
by distance
d.
In the example of Fig. 1c the warp 122 and weft 123 of the middle layer 12 are seen
to be aligned to form a criss-cross pattern, typically referred to as "plain weave".
However, a person skilled in the art will understand that many other alignments are
possible and that the choice of how to align the warp 122 and weft 123 yarns within
the middle layer 12 depends on the desired function of the final fabric. For instance
the alignment shown in Fig. 1c may be advantageous if it is desirable to achieve a
highly absorptive fabric since plain weave allows for a thick fabric with a large
number of weft yarns 123 over a given distance. Another alignment is shown in Fig.
1d, wherein a plurality of adjacent weft yarns 123 (here, three weft yarns) has the
same alignment within the middle layer 12 and are woven together on the same side
of the warp yarn 122. Such a configuration may be preferred in order to achieve a
resilient fabric suitable for e.g. upholstery since the alignment of the weft yarns
123 allows for compression of the three layers 10, 11, 12 in the vertical direction,
that is, thanks to the presented alignment the weft yarns 123 will not prevent the
warp yarn 122 from getting compressed, nevertheless the weft yarns 123 will still
provide a certain stability to the middle layer 12. Furthermore the warp 122, being
preferably made from a resilient material will provide stability and yet allow a certain
springiness to the fabric meaning the fabric will return to its original shape after
having been compressed.
[0040] Fig. 2a shows a part of a cross section taken somewhere along line IIa of fig 1.
This figure further clarifies that the intermediate interconnecting layer 12 alternates
between attaching to the upper 10 and to the lower 11 layers. The overall thickness
of the multilayer fabric is denoted T
tot, the thickness of the upper layer is denoted T
1, the thickness of the lower layer T
2 and the distance between the upper and lower layers is denoted
d.
[0041] The distance
d is predetermined before weaving is initiated and can be varied depending on the required
qualities of the final fabric material. A part of the interconnecting layer 12 which
extends between two adjacent layers over the distance
d is referred to as a "distancing layer". A large distance
d will lead to a higher flexibility in the structure whereas a short distance
d will render the fabric more stable and rigid.
[0042] It is possible to design a fabric according to the invention wherein T
tot essentially equals T
1 + T
2, which would mean that the intermediate layer 12 will alternate between being integrated
as a warp of the upper 10 layer, and being integrated as warp of the lower 11 layer,
having the function of holding the two layers together.
[0043] The thickness of the upper T
1 and lower T
2 layers may be varied by means of choosing a thicker or thinner yarn for the warp
and weft respectively when weaving that particular layer.
[0044] Fig. 2b is a cross section showing another example from a view corresponding to that
of fig. 2a where an upper 10 and a lower 11 layer are connected to each other by a
distancing interconnecting layer 12. The interconnecting layer 12 comprises a plurality
of distancing layers 121 and is alternating between being attached to the upper and
the lower layers respectively.
[0045] When weaving the fabric, the warp yarns 123 of the interconnecting layer 12 are integrated
with a section of the layer whereto it is meant to be attached (e.g. the upper) prior
to being transferred to the other layer (e.g. the lower) and attached in the same
manner.
[0046] In the example of fig. 2b the multiple layer fabric 1 is woven with a less number
of distancing layers 121 along a given length of the fabric compared to the fabric
of fig. 2a, meaning that during weaving longer sections of warp 122 of the intermediate
layer 12 are integrated within the upper 10 and the lower 11 layers respectively.
[0047] Fig. 2c illustrates another example of a multilayer fabric according to the present
invention, wherein three layers 10, 11, 15 extend substantially parallel to each other,
said three layers being interconnected by two interconnecting structures 12, 12' whereof
each comprises a plurality of distancing layers 121 (also referred to as distancing
bridges). It is to be understood that the interconnecting layers within one type of
multilayer fabric might be designed individually and independently of other layers.
This means that for instance the middle layer 15 may be provided with conductive filaments,
and that the surrounding interconnecting structures 12, 12' may be designed to protect
such conductive filaments from e.g. short circuits and/or outer wear. This may be
achieved e.g. by means of introducing bulky, non-conductive weft yarns within adjacent
interconnecting layers 12, 12'.
[0048] Moreover, as is seen in fig. 2c, the distance between the upper and the middle layers
d1 may be shorter than the distance between the middle and the lower layers
d2, and it is equally possible to vary the number of distancing layers 121 along a given
length of the fabric. All of the described variations of outlining the fabric according
to the present invention will result in a certain quality of the fabric, where examples
of such qualities might include high or low resistance, stability and/or rigidity
respectively.
[0049] Fig. 3a shows a part of a cross section taken somewhere along line IIIa of fig 1.
In this figure is seen how the interconnecting layer 12 extends between the two adjacent
upper 10 and lower 11 layers respectively, the warp yarns 122 of the interconnecting
layer 12 being directed essentially perpendicular to the direction of the warp yarns
in the upper 10 and lower 11 layers respectively. As is seen in the example of fig.
3a the interconnecting layer 12 also comprises weft yarns 123 extending horizontally
across the warp. These inner weft yarns 123 may be of any suitable material and may,
for instance, have certain function which enables for a specific functionality. In
fig. 3a two weft yarns 123 are inserted in the distancing layer, whereas fig. 3b shows
an example where a multiplicity of six weft yarns 123 are extending across the warp
yarns 122.
[0050] It is understood that the number of weft yarns may be increased, and that the interconnecting
layer may either consist of a thick fabric with dense weft and warp yarns or may equally
consist of a layer of multiple juxtaposed warp yarns without, or with a few only,
weft yarns. Each such variation of the fabric will give certain properties to the
resulting final fabric product. For instance, in one version of the fabric where the
interconnecting layer 12 comprises both a dense plurality of weft yarns 122, and a
large number of distancing layers 121 along a given length of the fabric will provide
a material will particularly good absorptive quality. In one example of the fabric
it will have an absorption factor between 0,7 and 1,1 for frequencies between 1 -
5 kHz.
[0051] In fig. 3c is shown another example of a cross section of a multiple layer fabric
according to the invention, where the cross section illustrates the fabric from a
perspective corresponding to the perspective of fig. 3a, but showing a different example.
Herein, a number of three layers 10, 11, 15 are extending substantially parallel to
each other. The upper 10 and the middle 15 layers represent one pair, and equally
the middle 15 and the lower 11 layers represents one pair. The layers of each pair
are connected to each other by integrated woven interconnecting layers 12, 12'. Each
of the two interconnecting layers 12, 12' comprises warp yarns 122, preferably polyester
warp, and preferably also a number of weft yarns 123. In the example of fig. 3c it
is possible that the uppermost interconnecting layer 12' acts as an insulator of the
lowermost interconnecting layer 12, meaning any conductive filaments that exist within
the lowermost distancing layers of the fabric will be shielded and protected from
e.g. a short circuit by the uppermost interconnecting layer 12'.
[0052] Figs. 2d and 3d illustrates yet another example of a cross section of the fabric
according to the present invention, which cross section 2d corresponds to the perspective
of fig. 2a, and cross section 3d corresponds to the perspective of fig. 3a.
[0053] As is seen in fig. 2d the fabric is woven in such a way that the distance
d between the upper 10 and the lower layers 11 is varied for each distancing bridge
121 of the intermediate layer 12. This is achieved by changing the length of the distancing
bridges 121 of the intermediate layer 12 along the length of the woven fabric. The
result of such a design is a fabric which presents a wave-formed profile. Such a fabric
may provide advantages e.g. as sound dampening material, since the wavy surface will
be facing different directions and will therefore absorb sound equally effectively
no matter where the source of emitted sound is located in relation to the fabric itself.
[0054] Fig 3d shows a cross section of the same example as in fig. 2d, taken along line
IIId of fig. 2d. An intermediate layer 12 creates a distance d between the upper 10
and the lower 11 layers, only in this example the distance d varies along the length
of the fabric resulting in a wave formed uppermost surface 13 and a wave formed lowermost
surface 14. In the example of fig. 3d the uppermost 13 and the lowermost 14 surfaces
are linear along a direction corresponding to a direction across the short side 2
of a piece of fabric. It is possible to let this surface embrace a wave shaped form
alike the undulate surface of the profile in fig. 2d.
[0055] Fig. 4 shows a design diagram representing an example of a repeating unit of a multilayer
fabric according to the present invention. The fabric of the present example is a
16-shaft three layer fabric having an upper layer, an intermediate interconnecting
layer and a lower layer, each layer respectively comprising warp and weft yarns.
[0056] The numerals of 1 - 16 denote upper layer warp, interconnecting layer warp and lower
layer warp yarns and the numerals of 1'- 42' denote upper layer weft, interconnecting
layer weft and lower layer weft yarns.
[0057] Referring to numerals which denote the weft yarns, only 1'- 4' and 39'- 42' are shown
explicitly in fig. 4, however, it is understood that the numerals 5' - 38' are represented
as well by the corresponding intermediate rows of the design diagram.
[0058] In the design diagram in fig. 4 indicated at numerals 4, 8, 12 and 16 are warp yarns
of the interconnecting layer, indicated at numerals 1, 2, 5, 6, 9, 10, 13 and 14 are
warp yarns of the upper layer and indicated at numerals 3, 7, 11, and 15 are warp
yarns of the lower layer of the fabric according to the invention.
[0059] Furthermore, in the design diagram in fig. 4 indicated at numerals 1'-3' and 25'
- 29' are weft yarns of the lower layer, indicated at numerals 4' - 8' and 22' - 24'
are weft yarns of the upper layer and indicated at numerals 9' - 21' and 30' - 42'
are weft yarns of the interconnecting layer.
[0060] In this diagram a mark Δ means that an upper layer warp lies over an upper layer
weft; a mark o means that a lower layer warp lies over a lower layer weft; the marks
◊, c, Θ and / means that an interconnecting layer warp lies over an interconnecting
layer weft; the mark ≈ means weaving of weft within the lower layer; the marks - or
• means weaving of weft within the upper layer; and ∞ means weaving of weft within
the intermediate interconnecting layer.
[0061] When weaving a fabric according to the diagram of fig. 4 the weaving proceeds in
the following way. Warp and weft yarn for each of the different layers (upper, intermediate
and lower layers) are arranged within the weaving machine, and the warp yarns are
brought through their respective heddles. When starting weaving the machine begins
with the weft corresponding to numerals 1' and proceeds upwards according to increasing
numerals: 2', 3', 4' and so on, up to 42'.
[0062] Firstly the machine will weave in the lower layer (1'-3') after which it weaves in
the upper layer (4'-8'). Then, weaving in the interconnecting layer will take place
(9'-21') and the warps of the intermediate layer is elevated by the corresponding
shaft so that the warps are positioned above the upper layer and are integrated with
the warp yarns of this upper layer. Again, weaving in the upper layer will proceed
(22'-24'), followed by weaving in the lower layer (25'-29'). Finally weaving in the
interconnecting layer (30'-42') and redirecting this layer by lowering the corresponding
shaft to be part of the lower layer is concluding the cycle of the given example,
which is then repeated.
[0063] Figure 5a is a cross sectional view taken along the lines Va and Vb in fig. 4 at
weft yarns 1' and 2' respectively, where Va is represented by yarn 51 and Vb is represented
by yarn 52.
[0064] In a similar manner, fig. 5b is a cross sectional view taken along the lines Vc and
Vd in fig. 4 at weft yarns 3' and 4' respectively. Here, Vc is represented by yarn
53 and Vd is represented by yarn 54.
[0065] Fig. 6b is a cross sectional view taken along the lines VIa and VIb in fig. 4 at
warp yarns 16 and 15 respectively, where VIa is represented by yarn 61 and VIb is
represented by yarn 62. Moreover, fig. 6b is a cross sectional view taken along the
lines VIc and VId in fig. 4, at warp yarns 14 and 13 respectively. VIc corresponds
to yarn 63 and VId corresponds to yarn 64.
[0066] Figs. 7a and 7b are illustrating how a system of warp yarns may be arranged in order
to create a certain functionality of the fabric. In these figures five warp yarns
125, 126, 127, 128, 129 represent a profile according to an example of the multilayer
fabric.
[0067] Two yarns 125 and 129 represent the warp or the upper and the lower layers respectively,
and three yarns 126, 127 and 128 represent warps that belong to the interconnecting
layer of the fabric. (It is to be understood that in reality the interconnecting layer
12 comprises many more parallel warp yarns that are not shown in fig. 7a for clarifying
reasons.) One warp yarn 126 is made out of conductive filaments, or out of a material
constituting a mix between non-conductive and conductive materials. Examples of such
materials may be carbon, silver, copper or other metals and/or alloys. When weaving
the fabric the conductive warp 126 is brought to surface the fabric at certain limited
regions whereby the warp yarns create a cushion 7 of conductive filaments. Cooperating
yarns 127, 128 are brought along with said conductive yarn 126 and may surface with
it e.g. in order to create a distancing structure 71 within said cushion 7 and/or
provide isolation protection 127 whereby short circuits are avoided.
[0068] The result of such a design is a number of protruding conductive cushions 7 which
are surfacing the fabric 1 at predetermined sites, where the locations of said sites
are decided during the outline of a design diagram for weaving. A fabric according
to this particular example is seen in fig. 7b wherein is shown the upper surface of
a piece of fabric which is woven with a number of surfacing conductive cushions 7.
[0069] At the portions of the fabric where no conductive cushions are required the warps
126, 127, 128 are kept in between the warp yarns 125, 129 of the outer upper and lower
layers 10, 11. A fabric with conductive spots, e.g. in the form of said cushions 7,
may be used e.g. for sensing pressure on mattress covers in hospitals, where it may
be important to monitor lying patients in order to avoid bedsores. In such an application
the conductive cushions would represent electrodes that are brought into contact with
the person as he/she lies upon the fabric with such an outline.
[0070] It is possible that a warp filament of the intermediate layer 12 never surfaces,
but elongates in between the two adjacent layers 10, 11. Such a version may provide
a way of heating the fabric from the inside. By adding a voltage over the conductive
filaments the filaments will heat up, which in its turn will warm up the surrounding
fabric.
[0071] Said conductive yarn 126 may be replaced by any kind of yarn, conductive or non-conductive,
whereby the choice of having non-conductive yarns will still lead to a certain surface
structure corresponding to surface comprising protruding cushions as shown in fig.
7b.
[0072] The invention is not to be seen as limited by the embodiments described above, but
can be varied within the scope of the appended claims. For instance it is understood
that the fabric may compose three, five or more layers which are woven simultaneously
in accordance with the inventive method. Furthermore it is possible that all layers
are woven of the same kind of material and, equally, that each of the respective layers
is made out of a yarn type which is different from the other ones.
1. A three-dimensional multilayer woven fabric comprising at least two woven layers (10,
11) arranged to extend substantially parallel to each other, and where said woven
fabric (1) further comprises a woven interconnecting support structure (12) interposed
between the at least two layers (10, 11) and being arranged to connect the at least
two layers (10, 11) with each other,
characterized in that said interconnecting support structure (12) comprises one single layer of warp yarn
(122) and weft yarn (123), wherein said warp yarn (122) is arranged to be integrated
with and extend between, and substantially perpendicular against, the planes defined
by said upper and lower adjacent two layers in an alternating manner thus forming
a single undulating structure, and wherein said warp yarn (122) in the interconnecting
support structure (12) is made of a resilient material, so that said interconnecting
support structure (12) will return to its original shape after having been compressed.
2. A three-dimensional multilayer woven fabric according to claim 1 characterized in that said warp yarn (122) is made of polyester monofilament yarn.
3. A three-dimensional multilayer woven fabric according to claim 1, or 2 characterized in that said interconnecting structure (12) comprises a plurality of distancing layers (121)
each whereof is extending between the at least two adjacent layers (10, 11), and wherein
said distancing layers are arranged to distance the two adjacent layers (10, 11) from
each other with a distance (d).
4. A three-dimensional multilayer woven fabric according to claim 3, characterized in that said fabric comprises three layers (10, 11, 15) extending substantially parallel
to each other in such a way representing one upper (10), one middle (15) and one lower
(11) layer, said upper (10) and middle (15) layers representing one pair, and said
middle (15) and lower (11) layers representing another pair, each pair of layers comprising
an interconnecting structure (12, 12') with a plurality of distancing layers (121).
5. A three-dimensional multilayer woven fabric according to any of claims 1-4 characterized in that said interconnecting structure (12, 12') is a continuous woven layer arranged to
extend back and forth between two adjacent layers (10, 11, 15) by means of a weaving
process.
6. A three-dimensional multilayer woven fabric according to claim 5 characterized in that the warp yarn (122) of said interconnecting structure (12, 12') partially and discontinuously
will be integrated with the warp of the adjacent two layers (10, 11, 15) so that they
alternate between the upper (10) and the lower (11) layer respectively.
7. A three-dimensional multilayer woven fabric according to any of claims 1 - 6 characterized in that at least one of said weft yarns (123) within said continuous interconnecting structure
(12, 12') is at least partially made out of a conductive material, such as copper,
silver or carbon.
8. A three-dimensional multilayer woven fabric according to any previous claims characterized in that any or all of the at least two layers (10, 11, 15) and/or the interconnecting structure
(12, 12') comprise yarn made of a conductive material, such as copper, silver or carbon.
9. A three-dimensional multilayer woven fabric according to any of previous claims characterized in that said interconnecting structure (12, 12') comprises a system of warp yarns (126, 127,
128) wherein each of the warp yarns (126, 127, 128) can be made to protrude through
the adjacent upper and/or lower layers (10, 11) of the fabric according to the invention.
10. A three-dimensional multilayer woven fabric according to any of previous claims characterized in that said woven fabric has an absorption factor for sound waves of at least 0.4, preferably
at least 0.7 and even more preferably at least 0.9 for 500 Hz.
11. A three-dimensional multilayer woven fabric according to any of previous claims characterized in that said woven fabric has an absorption factor for sound waves of at least 0.5, preferably
at least 0.7 and even more preferably at least 0.9 for frequencies between 1 - 5 kHz.
12. A method for producing a three-dimensional multilayer woven fabric according to anyone
of the previous claims comprising the steps of:
- providing a loom/apparatus for weaving;
- using the loom for weaving at least one first layer (10) of fabric;
- using the loom for weaving at least one second layer (11) of fabric; characterized in the following steps:
- simultaneously weaving said at least first (10) and second layers (11) in the loom;
and
- weaving at least one third intermediate layer (12) within the loom simultaneously
with the at least first (10) and second layers (11), which intermediate layer (12)
is arranged to be continuously undulated in such a way back and forth between the
adjacent first and second layers during weaving thus forming a plurality of distancing
layers (121) which are integrated with, and are interconnecting, said two adjacent
layers;
wherein all of the above mentioned steps are carried out simultaneously within the
loom to instantly produce a three-dimensional multilayer woven fabric (1).
1. Dreidimensionales mehrschichtiges Gewebe, umfassend mindestens zwei Webschichten (10,
11), die angeordnet sind, um im Wesentlichen parallel zueinander zu verlaufen, und
wobei das Gewebe (1) ferner eine gewebte Verbindungsstützstruktur (12) aufweist, die
sich zwischen den mindestens zwei Schichten (10, 11) befindet und angeordnet ist,
um die mindestens zwei Schichten (10, 11) miteinander zu verbinden,
dadurch gekennzeichnet, dass die Verbindungsstützstruktur (12) eine einzelne Schicht Kettgarn (122) und Schussgarn
(123) aufweist, wobei das Kettgarn (122) angeordnet ist, um in die Ebenen, die durch
die oberen und unteren angrenzenden beiden Schichten in alternierender Weise definiert
sind, integriert zu sein und zwischen ihnen und im Wesentlichen senkrecht dazu zu
verlaufen, um somit eine einzelne wellenförmige Struktur zu bilden, und wobei das
Kettgarn (122) in der Verbindungsstützstruktur (12) aus einem elastischen Material
besteht, sodass die Verbindungsstützstruktur (12) wieder ihre ursprüngliche Form annimmt,
nachdem sie komprimiert worden ist.
2. Dreidimensionales mehrschichtiges Gewebe nach Anspruch 1, wobei das Kettgarn (122)
aus Polyester-Monofilamentgarn besteht.
3. Dreidimensionales mehrschichtiges Gewebe nach Anspruch 1 oder 2, dadurch gekennzeichnet, dass die Verbindungsstützstruktur (12) mehrere Abstand schaffende Schichten (121) umfasst,
von denen jede zwischen den mindestens zwei angrenzenden Schichten (10, 11) verläuft,
und wobei die Abstandsschichten angeordnet sind, um die beiden angrenzenden Schichten
(10, 11) mit einem Abstand (d) voneinander zu beabstanden.
4. Dreidimensionales mehrschichtiges Gewebe nach Anspruch 3, dadurch gekennzeichnet, dass das Gewebe drei Schichten (10, 11, 15) aufweist, die im Wesentlichen parallel zueinander
auf eine Weise verlaufen, dass sie eine obere (10), eine mittlere (15) und eine untere
(11) Schicht darstellen, wobei die obere (10) und die mittlere (15) Schicht ein Paar
darstellen und die mittlere (15) und die untere (11) Schicht ein anderes Paar darstellen,
wobei jedes Paar von Schichten eine Verbindungsstützstruktur (12, 12') mit mehreren
Abstandsschichten (121) aufweist.
5. Dreidimensionales mehrschichtiges Gewebe nach einem der Ansprüche 1 bis 4, dadurch gekennzeichnet, dass die Verbindungsstützstruktur (12, 12') eine kontinuierliche gewebte Schicht ist,
die mittels eines Webvorgangs angeordnet ist, um zwischen zwei angrenzenden Schichten
(10, 11, 15) hin und her zu verlaufen.
6. Dreidimensionales mehrschichtiges Gewebe nach Anspruch 5, dadurch gekennzeichnet, dass das Kettgarn (122) der Verbindungsstützstruktur (12, 12') mit der Kette der angrenzenden
beiden Schichten (10, 11, 15) partiell und nicht kontinuierlich integriert ist, sodass
sie zwischen der oberen (10) und der unteren (11) Schicht alternieren.
7. Dreidimensionales mehrschichtiges Gewebe nach einem der Ansprüche 1 bis 6, dadurch gekennzeichnet, dass mindestens ein Schussgarn (123) in der kontinuierlichen Verbindungsstützstruktur
(12, 12') mindestens partiell aus einem leitfähigen Material wie beispielsweise Kupfer,
Silber oder Kohlenstoff besteht.
8. Dreidimensionales mehrschichtiges Gewebe nach einem der vorhergehenden Ansprüche,
dadurch gekennzeichnet, dass eine oder alle der mindestens zwei Schichten (10, 11, 15) und/oder die Verbindungsstützstruktur
(12, 12') Garn umfassen, das aus einem leitfähigen Material wie beispielsweise Kupfer,
Silber oder Kohlenstoff besteht.
9. Dreidimensionales mehrschichtiges Gewebe nach einem der vorhergehenden Ansprüche,
dadurch gekennzeichnet, dass die Verbindungsstützstruktur (12, 12') ein System aus Schussgarnen (126, 127, 128)
aufweist, wobei jedes der Schussgarne (126, 127, 128) dazu gebracht werden kann, durch
die angrenzende obere und/oder untere Schicht (10, 11) des erfindungsgemäßen Gewebes
hindurch hervorzustehen.
10. Dreidimensionales mehrschichtiges Gewebe nach einem der vorhergehenden Ansprüche,
dadurch gekennzeichnet, dass das Gewebe bei 500 Hz einen Absorptionsfaktor für Schallwellen von mindestens 0,4,
vorzugsweise von mindestens 0,7 und insbesondere von mindestens 0,9 aufweist.
11. Dreidimensionales mehrschichtiges Gewebe nach einem der vorhergehenden Ansprüche,
dadurch gekennzeichnet, dass das Gewebe bei Frequenzen von 1 bis 5 kHz einen Absorptionsfaktor für Schallwellen
von mindestens 0,5, vorzugsweise von mindestens 0,7 und insbesondere von mindestens
0,9 aufweist.
12. Verfahren zum Herstellen eines dreidimensionalen mehrschichtigen Gewebes nach einem
der vorhergehenden Ansprüche, umfassend die folgenden Schritte:
- Bereitstellen eines Webstuhls/einer Webmaschine;
- Verwenden des Webstuhls zum Weben mindestens einer ersten Gewebeschicht (10);
- Verwenden des Webstuhls zum Weben mindestens einer zweiten Gewebeschicht (11);
gekennzeichnet durch die folgenden Schritte:
- gleichzeitiges Weben mindestens der ersten (10) und der zweiten Schicht (11) in
dem Webstuhl; und
- Weben mindestens einer dritten Zwischenschicht (12) in dem Webstuhl gleichzeitig
mit der mindestens ersten (10) und zweiten Schicht (11), wobei die Zwischenschicht
(12) angeordnet ist, um zwischen der angrenzenden ersten und zweiten Schicht während
des Webens kontinuierlich derart vor und zurück gewellt zu werden, sodass mehrere
Abstandsschichten (121) gebildet werden, die mit den beiden angrenzenden Schichten
integriert sind und diese verbinden;
wobei alle vorstehend genannten Schritte gleichzeitig in dem Webstuhl ausgeführt werden,
um sofort ein dreidimensionales mehrschichtiges Gewebe (1) hervorzubringen.
1. Étoffe tissée multicouche tridimensionnelle comprenant au moins deux couches tissées
(10, 11) agencées de façon à s'étendre sensiblement parallèlement l'une à l'autre,
ladite étoffe non tissée (1) comprenant en outre une structure support de liaison
tissée (12) interposée entre les au moins deux couches (10, 11) et agencée pour relier
les au moins deux couches (10, 11) l'une à l'autre, caractérisée en ce que ladite structure support de liaison (12) comprend une seule couche de fil de chaîne
(122) et de fil de trame (123), ledit fil de chaîne (122) étant agencé de façon à
s'intégrer aux plans définis par lesdites deux couches adjacentes supérieure et inférieure
en alternance et à s'étendre entre eux, et sensiblement perpendiculairement à eux,
en formant ainsi une unique structure ondulante, et ledit fil de chaîne (122) dans
la structure support de liaison (12) était fait d'un matériau résilient, telle sorte
que ladite structure support de liaison (12) revienne à sa forme originelle après
avoir été comprimée.
2. Étoffe tissée multicouche tridimensionnelle selon la revendication 1, caractérisée en ce que ledit fil de chaîne (122) est fait d'un fil monofilament de polyester.
3. Étoffe tissée multicouche tridimensionnelle selon la revendication 1 ou la revendication
2, caractérisée en ce que ladite structure de liaison (12) comprend une pluralité de couches d'espacement (121),
s'étendant chacune entre les au moins deux couches adjacentes (10, 11), et lesdites
couches d'espacement étant agencées de façon à éloigner les deux couches adjacentes
(10, 11) l'une de l'autre d'une distance (d).
4. Étoffe tissée multicouche tridimensionnelle selon la revendication 3, caractérisée en ce que ladite étoffe comprend trois couches (10, 11, 15) s'étendant sensiblement parallèlement
les unes aux autres de façon à représenter une couche supérieure (10), une couche
médiane (15) et une couche inférieure (11), lesdites couches supérieure (10) et médiane
(15) représentant une paire, et lesdites couches médiane (15) et inférieure (11) représentant
une autre paire, chaque paire de couches comprenant une structure de liaison (12,
12') dotée d'une pluralité de couches d'espacement (121).
5. Étoffe tissée multicouche tridimensionnelle selon l'une quelconque des revendications
1 à 4, caractérisée en ce que ladite structure de liaison (12, 12') est une couche tissée continue agencée de façon
à s'étendre d'un côté à l'autre entre deux couches (10, 11, 15) adjacentes au moyen
d'un procédé de tissage.
6. Étoffe tissée multicouche tridimensionnelle selon la revendication 5, caractérisé en ce que le fil de chaîne (122) de ladite structure de liaison (12, 12') s'intègre partiellement
et de manière discontinue à la chaîne des deux couches adjacentes (10, 11, 15) de
manière à alterner entre la couche supérieure (10) et la couche inférieure (11), respectivement.
7. Étoffe tissée multicouche tridimensionnelle selon l'une quelconque des revendications
1 à 6, caractérisée en ce qu'au moins un desdits fils de trame (123) dans ladite structure de liaison (12, 12')
continue est au moins partiellement fait d'un matériau conducteur, comme le cuivre,
l'argent ou le carbone.
8. Étoffe tissée multicouche tridimensionnelle selon l'une quelconque des revendications
précédentes, caractérisée en ce que l'une quelconque ou toutes les au moins deux couches (10, 11, 15) et/ou la structure
de liaison (12, 12') comprennent un fil fait d'un matériau conducteur, comme le cuivre,
l'argent ou le carbone.
9. Étoffe tissée multicouche tridimensionnelle selon l'une quelconque des revendications
précédentes, caractérisée en ce que ladite structure de liaison (12, 12') comprend un système de fils de chaîne (126,
127, 128) dans lequel chaque fil de chaîne (126, 127, 128) peut être amener à dépasser
à travers les couches supérieure et/ou inférieure (10, 11) adjacentes de l'étoffe
selon l'invention.
10. Étoffe tissée multicouche tridimensionnelle selon l'une quelconque des revendications
précédentes, caractérisée en ce que ladite étoffe tissée présente un facteur d'absorption pour les ondes sonores d'au
moins 0,4, de préférence d'au moins 0,7 et mieux encore d'au moins 0,9 pour 500 Hz.
11. Étoffe tissée multicouche tridimensionnelle selon l'une quelconque des revendications
précédentes, caractérisée en ce que ladite étoffe tissée présente un facteur d'absorption pour les ondes sonores d'au
moins 0,5, de préférence d'au moins 0,7 et mieux encore d'au moins 0,9 pour les fréquences
comprises entre 1 et 5 kHz.
12. Procédé de production d'une étoffe tissée multicouche tridimensionnelle selon l'une
quelconque des revendications précédentes, comprenant les étapes suivantes :
- fournir un métier à tisser/appareil pour le tissage ;
- utiliser le métier à tisser pour tisser au moins une première couche (10) d'étoffe
;
- utiliser le métier à tisser pour tisser au moins une deuxième couche (11) d'étoffe
;
caractérisé par les étapes suivantes :
- tissage simultané desdites au moins première (10) et deuxième couche (11) dans le
métier à tisser ; et
- tissage d'au moins une troisième couche intermédiaire (12) dans le métier à tisser
simultanément à la première (10) et à la deuxième couche (11), cette couche intermédiaire
(12) étant agencée pour être ondulée en continu de manière à aller d'un côté à l'autre
entre la première et la deuxième couche adjacentes pendant le tissage en formant ainsi
une pluralité de couches d'espacement (121) qui s'intègrent dans lesdites deux couches
adjacentes, et y sont reliées,
dans lequel toutes les étapes susmentionnées sont mises en oeuvre simultanément dans
le métier à tisser pour produire directement une étoffe tissée multicouche tridimensionnelle
(1).