FIELD OF INVENTION

This invention relates to the field of textiles, primarily in relation to a particular woven camouflage patterned textile and a method for producing the camouflage patterned textile.

BACKGROUND

Organised armed forces all around the world ubiquitously rely on camouflage patterned attire which enables the troops to blend into the environment where they are deployed. This camouflage patterned attire is necessary for concealment from enemy surveillance, and consequently, safety of the troops. Failure of the camouflage patterned attire to effectively conceal the troops from enemy surveillance would be detrimental to the safety of the troops, possibly leading to unnecessary injuries and loss of lives amongst the troops.

Given the advances in night vision viewing apparatus, it would be most unwise to use camouflage patterned attire which is only effective in lit conditions and ineffective in conditions where night vision viewing apparatus are employed. It is imperative for the safety of the troops that the camouflage patterned attire is also able to offer concealment during instances when night vision viewing apparatus are employed by the enemy. Most of the night vision viewing apparatus rely on near infra-red (NIR) sensors, thus the camouflage patterned attire used by the troops should also be effective when the troops are viewed using night vision viewing apparatus relying on NIR sensors. In this regard, it is essential for NIR values of the various patterns on the camouflage patterned attire to be as closely matched with the NIR values of the ambient environment as possible.

It is typical for camouflage patterned designs to comprise unevenly-shaped patches of varying colours, where the patches may be both overlaid on each other and arranged alongside each other. Typically, a base colour of the camouflage patterned attire is selected primarily in accordance with an environment of deployment, with the unevenly-shaped colour patches being part of a colour scheme which matches the base colour of the camouflage patterned attire.

A common process for producing a fabric substrate for the camouflage patterned attire is continuous dye printing, which involves adhering dye layers one on top of another only when the previous dye layer has dried. Typically, each dye layer does not have any significant time to react (bind) with the fabric substrate. Furthermore, while the overlaying of the dye layers results in the fabric substrate with the desired camouflage patterns, the camouflage patterns are not precisely printed. In addition, the dye printing process does not ensure colour-fastness during use and washing, and as such, the desired camouflage patterns eventually fade due to the washing off of the dye layers which results from both the lack of time which the dye layers have to react with the fabric substrate, and because of the typical use of less effective binders. It is evident that faded camouflage patterns become less effective for the purpose of concealment of troops. This loss of effectiveness affects the concealment of troops both in both lit conditions and conditions where night vision viewing apparatus using NIR sensors are employed by the enemy. While the loss of effectiveness in lit conditions is evident due to a faded visual appearance of the camouflage patterned attire, the loss of effectiveness in conditions where night vision viewing apparatus using NIR sensors are employed is due to change of the NIR value of regions of the fabric substrate. The change of the NIR value of regions of the fabric substrate causes troops wearing the fabric substrate to "stand out" from the background when the troops are viewed using the night vision viewing apparatus using NIR sensors.

In addition, use of the continuous dye printing process to produce the fabric substrate for the camouflage patterned attire results in a fabric substrate with inconsistent patterns and correspondingly, inconsistent NIR value of regions of the fabric substrate. This is undesirable. This inconsistency is inherent due to the use of the continuous dye printing process as regulation/control pertaining to the drying and overlaying of the dye layers is difficult. Thus, it is difficult to ensure an effectiveness of the fabric substrate (in relation to both pattern appearance and NIR ratings) which is made using the continuous dye printing process during instances where night vision viewing apparatus using NIR sensors is used to view the fabric substrate. In this regard, it is also difficult to produce a fabric substrate with definable/customizable regions of different NIR values using the continuous dye printing process.

Furthermore, as mentioned earlier, the continuous dye printing process involves adhering dye layers one on top of another only when the previous dye layer has dried. This process is tedious and it is evident that a plurality of process runs is necessary to produce the fabric substrate with the required patterns. Typically, the greater the number of process runs to produce an object, the higher a cost to produce the object. It is also evident that the cost would be increased if the fabric substrate had the required patterns printed on both faces of the fabric substrate. Thus double-side fabric substrates using the continuous dye printing process to produce a reversible fabric substrate would be rather costly especially if both faces of the fabric substrate are not printed concurrently.

Based on the aforementioned, it is evident that the continuous dye printing process to produce a patterned fabric substrate is flawed.

SUMMARY

In a first aspect, there is provided a method for producing a camouflage patterned textile with patterns on at least one face of the camouflage patterned textile. The method includes dyeing each of a plurality of either yarns or multi-ply threads; configuring a controller of a weaving machine to use the plurality of either yarns or multi-ply threads to produce the camouflage patterned textile; and running the weaving machine with the controller controlling the weaving machine to produce the camouflage patterned textile. It is advantageous that the camouflage patterned textile with the patterns on at least one face is produced with a single running of the weaving machine and the patterns on both faces of the patterned textile are not identical. The weaving machine may preferably be configurable to weave the camouflage patterned textile with at least two layer weaves.

The dyeing of each of the plurality of either yarns or multi-ply threads is by either dope dyeing or yarn dyeing. Advantageously, the patterns on the camouflage patterned textile are colour-fast. Consequently, the camouflage patterned textile may be used for applications such as, for example, clothing, clothing accessories, outdoor equipment and so forth.

It is preferable that each of the plurality of either yarns or multi-ply threads are made from either natural or synthetic fibres. An NIR value of each of the plurality of either yarns or multi-ply threads is an NIR value of the dye used for dyeing. It is advantageous that the colour-fastness of the camouflage patterned textile maintains the NIR value of each of the plurality of either yarns or multi-ply threads used to produce the camouflage patterned textile. Consequently, the NIR value of a region of the camouflage patterned textile is dependent on the NIR value of either the yarn(s) or the multi-ply thread(s) used for the region of the camouflage patterned textile. The NIR value of various regions of the camouflage patterned textile affects an appearance of the camouflage patterned textile when viewed using night vision viewing apparatus using NIR sensors.

The method may further include determining the NIR value of either the yarn(s) or the multi-ply thread(s) after the dyeing of either the yarn(s) or the multi-ply thread(s).

In a second aspect, there is provided a woven camouflage patterned textile with camouflage patterns on at least one face of the woven camouflage patterned textile, wherein both faces of the woven camouflage patterned textile are not identical. The woven camouflage textile may preferably be woven with at least two layers. Advantageously, the patterns on the woven camouflage patterned textile are colour-fast. Consequently, the woven camouflage patterned textile may be used for applications such as, for example, clothing, clothing accessories, outdoor equipment and the like.

It is preferable that each the plurality of either yarns or multi-ply threads are made from either natural or synthetic fibres. It is advantageous that an NIR value of each of the plurality of either yarns or multi-ply threads is an NIR value of the dye used for dyeing. The colour-fastness of the woven camouflage patterned textile advantageously maintains the NIR value of each of the plurality of either yarns or multi-ply threads used to form the woven camouflage patterned textile. The NIR value of a region of the woven camouflage patterned textile may be dependent on the NIR value of either the yarn(s) or the multi-ply thread(s) used for the region of the patterned textile. The NIR value of various regions of the woven camouflage patterned textile consequently affects an appearance of the woven camouflage patterned textile when viewed using night vision viewing apparatus using NIR sensors.

DESCRIPTION OF DRAWINGS

In order that the present invention may be fully understood and readily put into practical effect, there shall now be described by way of non-limitative example only preferred embodiments of the present invention, the description being with reference to the accompanying illustrative drawings.

Figure 1 shows a process flow for a method of the present invention.

Figure 2 shows a view of a first face of a woven camouflage patterned textile of the present invention.

Figure 3 shows a magnified view of a portion of the first face of the woven camouflage patterned textile of the present invention.

DESCRIPTION OF PREFERRED EMBODIMENTS It should be appreciated that the description of the preferred embodiments is for clarification purposes, and is not meant to be limiting in instances where non-material variations in either details of design or construction are conceivable.

Referring to Figure 1 , there is shown a first aspect of the present invention, namely, a process flow of a method 20 for producing a camouflage patterned textile with patterns on at least one face of the camouflage patterned textile. The method 20 will be described in relation to camouflage patterns as shown in Figure 2. The camouflage patterned textile made by the method 20 may be used for items such as, for example, clothing, clothing accessories, outdoor equipment, and so forth. The clothing accessories may include, for example, belts, wrist bands, neck bands, and so forth. The outdoor equipment may include, for example, backpacks, holster belt webbings, water bottle carriers, load bearing straps, and the like.

The method 20 may utilize warp yarns, weft yarns, multi-ply threads or any combination of the aforementioned materials. The method 20 may be used to produce camouflage patterned textiles which are either thick or thin. A thickness of the camouflage patterned textile produced by the method 20 may be dependent on the type of materials used in the method 20. Intended application(s) of the camouflage patterned textile may also affect both the thickness and the combination of materials used to produce the camouflage patterned textile. For example, it is likely that a belt will require the use of a thick camouflage patterned textile as the belt may need to be stiff to provide some structural back support for a wearer. Similarly, it is likely that a bandana will require the use of a thin camouflage patterned textile as the scarf may need to be soft to conform with a wearer's head.

The method 20 includes dyeing each of a plurality of either yarns or multi-ply twisted thread 22. The yarns or multi-ply threads may be made of a material such as, for example, natural fibres, and synthetic fibres. Examples of natural fibres include, for example, cotton, rayon, wool and so forth. The natural fibres may be in staple fibre form and spun into spun yarns. The spun yarns of natural fibres may be yarn dyed using either vat dyes (cotton, rayon) or acid dyes (wool).

In addition, examples of synthetic fibres include, for example, polyamide (nylon), polyester, acrylic, aramid (Kevlar), polyethylene (Spectra), polypropylene, and so forth. The synthetic fibres may be in continuous multifilament form. The synthetic fibres may be either dope dyed or yarn dyed. Dope dyeing of the synthetic fibres may be carried out by introducing pigment dyes into masterbatches of polymers during the yarn formation process for the synthetic fibres. The spun yarns of synthetic fibres may be yarn dyed using, for example, acid dyes (polyamide), vat dyes (polyamide), disperse dyes (polyester) and so forth.

It should be appreciated that the use of yarn dyeing enables optimal interaction between the dyes and the yarns. Similarly, dope dyeing also enables optimal interaction between the dyes and the polymers. This optimal interaction ensures that the NIR value of each yarn conforms to the NIR value of the dye. In addition, this optimal interaction also ensures colour fastness of either each of the plurality of yarns or each multi-ply twisted thread. The colour fastness of either each of the plurality of yarns or each multi-ply twisted thread used to produce the camouflage patterned textile may ensure that the patterns on the camouflage patterned textile are colour-fast. It is advantageous that the colour-fastness of the camouflage patterned textile maintains the NIR value of each of the plurality of yarns used to produce the camouflage patterned textile during an entire duration of use of the camouflage patterned textile.

In the method 20, there may be a check to determine the NIR value of either the yarn or the multi-ply thread 26 after the dyeing process. The check may ensure that each of either the plurality of yarns or the multi-ply threads is of a correct NIR value as per a specification of the camouflage patterned textile. If at least one of either the plurality of yarns or the multi-ply threads is of an incorrect NIR value, appropriate changes to either the plurality of yarns or the multi-ply threads may be performed. This may minimize incorrect usage and consequently wastage of either the plurality of yarns or the multi-ply threads when employing the method 20 to produce the camouflage patterned textile.

A controller of a weaving machine is configured to use either the plurality of yarns or the multi-ply threads to produce the camouflage patterned textile 28. It should be appreciated that the step of configuring the controller 28 may be done at any prior juncture, but this step needs to be performed before a beginning of the weaving process. The weaving machine may be able to weave the camouflage patterned textiles with at least two layer weaves. For example, the camouflage patterned textile may result from a layer woven from each of a warp yarn, and a weft yarn. The configuration of the controller may include, for example, defining patterns which are to be woven on a first face of the patterned textile, defining a number of weaving layers for the patterned textile, defining a woven length of the patterned textile, and so forth.

After the controller is configured, the weaving machine is run with the controller controlling all processes of the weaving machine to produce the camouflage patterned textile 30. The weaving machine may produce the camouflage patterned textile with the patterns on at least one face of the camouflage patterned textile. The camouflage patterned textile may be produced with a single running of the weaving machine. The single running of the weaving machine to produce the camouflage patterned textile advantageously minimizes production costs especially since camouflage patterns on dual faces may be created simultaneously. An example of the camouflage patterned textile 48 is shown in Figure 2.

Corresponding patterns on dual faces of the camouflage patterned textile 48 typically are not identical. It should be appreciated that corresponding patterns means either direct back-to-back patterns on the dual faces of the camouflage textile 48 or slightly offset back-to-back patterns on the dual faces of the camouflage textile 48. It is possible for a first face of the camouflage textile 48 to have camouflage patterns as per Figure 2, with the second face of the camouflage textile 48 being devoid of any camouflage patterns. It is also possible for the first face of the camouflage textile 48 to have camouflage patterns as per Figure 2, with the second face of the camouflage textile 48 having a similar camouflage pattern with a different colour layout. Finally, the first face of the camouflage textile 48 may have camouflage patterns as per Figure 2, while the second face of the camouflage textile 48 may also have identical camouflage patterns as per Figure 2, albeit in a blurred version with less distinct edge definitions.

Referring to Figure 3, there is shown a magnified view of a portion of the camouflage textile 48 as shown in Figure 2. It can be appreciated that the camouflage textile 48 produced using the method 20 contains camouflage patterns which comprises pixels of a plurality of colours.

The method 20 allows the NIR value of a region of the camouflage patterned textile 48 to be dependent on the NIR value of a dye(s) used for either the yam or the multi-ply thread used for the region of the camouflage patterned textile 48. Since the NIR value of various regions of the patterned textile 48 affects an appearance of the patterned textile 48 when viewed using night vision viewing apparatus, it is imperative that the NIR value of the various regions is correct to ensure a desired appearance of the patterned textile 48 when viewed using the night vision viewing apparatus which uses NIR sensors.

Referring to Figure 2, there is shown a second aspect of the present invention, namely, a woven camouflage patterned textile 48 with patterns on at least one face of the camouflage patterned textile 48. The camouflage patterned textile 48 may be used for clothing, clothing accessories, outdoor equipment, and so forth. The clothing accessories may include, for example, belts, wrist bands, neck bands, and so forth. The outdoor equipment may include, for example, backpacks, holster belt webbings, water bottle carriers, load bearing straps, and the like.

The camouflage patterned textile 48 may be made from warp yarns, weft yarns, multi-ply threads, or any combination of the aforementioned materials. A thickness of the camouflage patterned textile 48 may be dependent on the type of materials used in making the camouflage patterned textile 48. Intended application(s) of the camouflage patterned textile 48 may also affect both the thickness of the camouflage patterned textile 48. For example, it is likely that a belt will require the use of a thick camouflage patterned textile 48 as the belt may need to be stiff to provide some structural back support for a wearer. Similarly, it is likely that a bandana will require the use of a thin camouflage patterned textile 48 as the scarf may need to be soft to conform with a wearer's head.

The camouflage patterned textile 48 may be woven from a plurality of either yarns or multi-ply threads. The yarns or multi-ply threads may be made of a material such as, for example, natural fibres, and synthetic fibres. Examples of natural fibres include, for example, cotton, rayon, wool and so forth. The natural fibres may be in staple fibre form and spun into spun yarns. The spun yarns of natural fibres may be yarn dyed using either vat dyes (cotton, rayon) or acid dyes (wool).

In addition, examples of synthetic fibres include, for example, polyamide (nylon), polyester, acrylic, aramid (Kevlar), polyethylene (Spectra), polypropylene, and so forth. The synthetic fibres may be in continuous multifilament form. The synthetic fibres may be either dope dyed or yarn dyed. Dope dyeing of the synthetic fibres may be carried out by introducing pigment dyes into masterbatches of polymers during the yarn formation process for the synthetic fibres. The spun yarns of synthetic fibres may be yarn dyed using, for example, acid dyes (polyamide), vat dyes (polyamide), disperse dyes (polyester) and so forth.

It should be appreciated that the use of yarn dyeing enables optimal interaction between the dyes and the yarns. Similarly, dope dyeing also enables optimal interaction between the dyes and the polymers. This optimal interaction ensures that the NIR value of each yarn conforms to the NIR value of the dye. In addition, this optimal interaction also ensures colour fastness of either each of the plurality of yarns or each multi-ply twisted thread. The colour fastness of either each of the plurality of yarns or each multi-ply twisted thread used to produce the camouflage patterned textile 48 may ensure that the patterns on the camouflage patterned textile 48 are colour-fast. It is advantageous that the colour-fastness of the camouflage patterned textile 48 maintains the NIR value of each of the plurality of yarns used to produce the patterned textile during an entire duration of use of the camouflage patterned textile 48.

Corresponding patterns on dual faces of the camouflage patterned textile 48 typically are not identical. It should be appreciated that corresponding patterns means either direct back-to-back patterns on the dual faces of the camouflage patterned textile 48 or slightly offset back-to-back camouflage patterns on the dual faces of the camouflage patterned textile 48. It is possible for a first face of the camouflage textile 48 to have camouflage patterns as per Figure 2, with the second face of the camouflage textile 48 being devoid of any camouflage patterns. It is also possible for the first face of the camouflage textile 48 to have camouflage patterns as per Figure 2, with the second face of the camouflage textile 48 having a similar camouflage pattern with a different colour layout. Finally, the first face of the camouflage textile 48 may have camouflage patterns as per Figure 2, while the second face of the camouflage textile 48 may also have identical camouflage patterns as per Figure 2, albeit in a blurred version with less distinct edge definitions.

The NIR value of a region of the camouflage patterned textile 48 is dependent on the NIR value of a dye(s) used for either the yarn(s) or the multi-ply thread(s) used for the region of the camouflage patterned textile 48. Since the NIR value of various regions of the patterned textile 48 affects an appearance of the patterned textile 48 when viewed using night vision viewing apparatus, it is imperative that the NIR value of the various regions is correct to ensure a desired appearance of the camouflage patterned textile 48 when viewed using the night vision viewing apparatus which uses NIR sensors.

The camouflage patterned textile 48 may be woven with at least two layer weaves. For example, the camouflage patterned textile 48 may result from a layer woven from each of a warp yarn, and a weft yarn. In conclusion, it should be appreciated that the method 20 to produce the camouflage patterned textile 48 allows the camouflage patterned textile 48 to be produced as per a pre-defined visual pattern and a pre-defined NIR value (on a per region basis). In addition, the single run process of the method 20 also brings forth advantages in relation to lower production costs.

Whilst there has been described in the foregoing description preferred embodiments of the present invention, it will be understood by those skilled in the technology concerned that many variations or modifications in details of design or construction may be made without departing from the present invention.