Multilayer and multifunctional woven fabrics and methods of making the same

Abstract

A multilayer fabric includes at least a first woven fabric layer and a second woven fabric layer tacked to the first woven fabric layer. The first woven fabric layer provides a first functionality to the multilayer fabric, the second woven fabric layer provides a second functionality to the multilayer fabric, and the first functionality is different than the second functionality. A method for forming a multilayer fabric includes weaving a first fabric layer on a loom, the first fabric layer having a first functionality, weaving at least a second fabric layer on the loom, the second fabric layer having a second functionality different than the first functionality, and tacking the second fabric layer to the first fabric layer while the first fabric layer and the second fabric layer are on the loom. The multilayer fabric may include multiple fabric layers, such as from 2 to 8 fabric layers.

What is claimed is: 
     
         1 . A multilayer fabric comprising at least a first woven fabric layer and a second woven fabric layer tacked to the first woven fabric layer, wherein:
 the first woven fabric layer provides a first functionality to the multilayer fabric;   the second woven fabric layer provides a second functionality to the multilayer fabric; and   the first functionality is different than the second functionality.   
     
     
         2 . The multilayer fabric according to  claim 1 , wherein the first functionality and the second functionality are selected from one or more of warming, cooling, all season, flame resistance, antibacterial, odor control, retro-reflectivity, ultraviolet protection, friction resistance, wear resistance, energy resistance, water repellency, water proofing, wind resistance, thermal conductivity, electrical conductivity, stretch, non-stretch, softness, hand, slub, fabric smoothness, yarn size, printability, dyeability, color, color changing, pattern changing, responsivity, energy boosting, skin-moisturizing, infrared (IR) transmitting, IR reflecting, IR absorbing, ventilation, controllable shrinkage, sensing properties, aesthetic look, and aesthetic feel. 
     
     
         3 . The multilayer fabric according to  claim 1 , wherein the first woven fabric layer comprises first yarns woven into a first fabric construction, and the first functionality is provided by one or more of the first yarns and the first fabric construction. 
     
     
         4 . The multilayer fabric according to  claim 3 , wherein the first yarns are woven into the first fabric construction in both a warp direction and a weft direction, and the first yarns woven in the warp direction and the first yarns woven in the weft direction comprise an identical yarn type or a different yarn type. 
     
     
         5 . The multilayer fabric according to  claim 4 , wherein the first functionality is provided by the first yarns woven in the warp direction, the first yarns woven in the weft direction, or the first yarns woven in both the warp direction and in the weft direction. 
     
     
         6 . The multilayer fabric according to  claim 1 , wherein the second woven fabric layer comprises second yarns woven into a second fabric construction, and the second functionality is provided by one or more of the second yarns and the second fabric construction. 
     
     
         7 . The multilayer fabric according to  claim 6 , wherein the second yarns are woven into the second fabric construction in both a warp direction and a weft direction, and the second yarns woven in the warp direction and the second yarns woven in the weft direction comprise an identical yarn type or a different yarn type. 
     
     
         8 . The multilayer fabric according to  claim 7 , wherein the second functionality is provided by the second yarns woven in the warp direction, the second yarns woven in the weft direction, or the second yarns woven in both the warp direction and in the weft direction. 
     
     
         9 . The multilayer fabric according to  6 , wherein the first fabric construction comprises a first weave type and the second fabric construction comprises a second weave type and the first weave type and the second weave type are independently selected from a plain weave, a twill weave, a satin weave, a pile weave, a dobby weave, a knit-look weave, a rip-stop, derivatives thereof, and combinations thereof. 
     
     
         10 . The multilayer fabric according to  claim 1 , wherein the second woven fabric layer is tacked to the first woven fabric layer in a warp direction, a weft direction, or in both the warp direction and the weft direction. 
     
     
         11 . The multilayer fabric according to  claim 1 , further comprising air pockets between the second woven fabric layer and the first woven fabric layer resulting from tacking between the second woven fabric layer and the first woven fabric layer. 
     
     
         12 . The multilayer fabric according to  claim 11 , wherein the tacking is performed in a tunable pattern such that the air pockets are formed in the multilayer fabric in a tunable pattern with a tunable size. 
     
     
         13 . The multilayer fabric according to  claim 1 , wherein the first woven fabric layer and the second woven fabric layer are simultaneously woven on the same loom. 
     
     
         14 . The multilayer fabric according to  claim 13  wherein the first woven fabric layer and the second woven fabric layer are simultaneously woven using a single warp beam or a multiple warp beam. 
     
     
         15 . A garment formed from the multilayer fabric of  claim 1 . 
     
     
         16 . The garment according to  claim 15 , wherein the garment comprises a jacket, pants, jeans, hat, a shirt, an overall, workwear, or active wear. 
     
     
         17 . A method for forming a multilayer fabric, comprising:
 weaving a first fabric layer on a loom, the first fabric layer having a first functionality;   weaving at least a second fabric layer on the loom, the second fabric layer having a second functionality different than the first functionality; and   tacking the second fabric layer to the first fabric layer while the first fabric layer and the second fabric layer are on the loom.   
     
     
         18 . The method according to  claim 17 , wherein the loom comprises a single warp beam or a multiple warp beam. 
     
     
         19 . The method according to  claim 17 , further comprising:
 weaving at least a third fabric layer on the loom, the third fabric layer having a third functionality that is different than one or both of the first functionality and the second functionality; and   tacking the third fabric layer to one or both of the first fabric layer and the second fabric layer.   
     
     
         20 . The method according to  claim 17 , wherein the multilayer fabric comprises from 2 to 8 woven fabric layers.