TEXTILE MATERIAL AND METHOD OF FORMATION THEREOF

FIELD OF THE INVENTION The present invention relates to a textile material. In particular, but not exclusively, the present invention relates to a textile material that has improvements in relation to textile materials. Some embodiments relate to textiles that offer thermal stability and to a method of forming said textile materials. BACKGROUND

Textiles are known in the art and are formed from interlacing yarns to produce a flexible material. Properties of textile materials can differ greatly by using different yarns (such as colours, materials, thickness) and by using different interlacing techniques (such as weaving, knitting, crocheting). Furthermore, each of these techniques has a large number of variations. In this manner, textiles can be produced for a wide variety of different end uses.

One such end use is in the clothing industry where it is known to produce different textiles to suit the use of the clothing, dependent on the requirements of the wearer of the clothing. For example, a textile made for outer wear may be required to have an element of weather resistance, whereas a textile made to contact the skin may be required to be soft on the wearer's skin. It is an object of some aspects of the present invention to provide an improved textile material. It is an object of some aspects of the invention to provide an improved method of forming a textile material.

STATEMENT OF THE INVENTION

Embodiments of the present invention may be understood with reference to the appended claims.

Aspects of the present invention provide a method, a textile, an article such as a curtain, a cushion cover, a pillow case or a garment and a loom. In one aspect of the invention for which protection is sought there is provided a method of forming a textile material comprising weaving, in a single weaving operation, a first layer, the first layer comprising a warp comprising warp threads and a weft comprising weft threads, and a second layer, the second layer comprising at least a weft comprising weft threads, the single weaving operation comprising joining the second layer and the first layer by weaving as the material is woven.

Embodiments of the invention enable a textile to be fabricated in which two or more layers of material are joined during the weaving operation without a requirement to perform a post-weaving joining operation. The first and second layers may therefore be considered to be joined in a substantially seamless manner.

Advantageously the method may comprise weaving the weft of the second layer with the warp of the first layer to join the first and second layers.

Further advantageously the method may comprise weaving the weft of the second layer with the warp of the first layer at a plurality of locations across the warp of the second layer. This feature has the advantage that in the case the second layer comprises a weft and not a warp, sagging of the weft threads across the second layer may be prevented. This is because the weft threads of the second layer are stitched to the warp of the first layer by interweaving with the warp threads. The region in which the interweaving is provided may be referred to as an integrally woven seam.

The method may comprise forming the second layer to comprise a weft only and not a warp.

Advantageously the method may comprise joining the first layer and second layer at locations defining a recurring pattern being one selected from amongst a diamond pattern, square pattern, a rectangular pattern and a circular pattern.

The method may further comprise weaving, in the single weaving operation, a third layer, the third layer comprising a warp comprising warp threads and a weft comprising weft threads. The method may comprise weaving the third layer whereby the second layer forms an intermediate layer between the first layer and the third layer.

Thus the method allows a textile material having an inner layer (which may for example correspond to the first layer), an outer layer (which may for example correspond to the third layer) and a wadding layer (which may for example correspond to the second layer) therebetween. The textile may be formed to be suitable for a range of applications including the manufacture of jackets, trousers, sleeping bags, upholstery and any other suitable articles or applications.

The method may comprise weaving the weft of the second layer with the warp of the third layer at a plurality of locations spaced apart across the weft of the second layer.

By spacing apart these locations, the weft of the second layer is only compressed by the weaving at the spaced apart locations. This allows the portion of the weft between spaced apart locations to remain substantially uncompressed. It is to be understood that in the case the weft is arranged to trap air therein in order to enhance a thermal insulation characteristic thereof, compressing of the weft may compromise the thermal insulation characteristics thereof.

A region in which two layers are joined by weaving the weft of one layer with the warp of another may be referred to as a seam, the seam being integrally formed as part of the weaving operation by which the layers are formed. In the case that such a seam is formed between the second and third layers, the seam between the first and second layers and the seam between the second and third layers may be provided at the same or different respective locations.

The method may comprise weaving the weft of the second layer with the warp of the first and third layers at substantially the same plurality of locations across the weft of the second layer.

The weft of the second layer may comprise a wadding yarn.

The wadding yarn may comprise one or more stretch fibres.

The wadding yarn may be a filament yarn or a spun yarn. The wadding yarn may comprise more than 50 filaments per yarn, optionally more than 60 filaments per yarn. The wadding yarn may comprise filament yarns comprising less than 100 filaments per yarn, optionally less than 90 filaments per yarn.

The wadding yarn may comprise filament yarns comprising between about 70 and 80 filaments per yarn.

Optionally the method may comprise forming the second layer to comprise a warp, the warp comprising warp threads and a weft, the weft comprising weft threads.

Advantageously the method may comprise joining the first and second layers by weaving the warp of the first and second layers with a common weft to form a common layer.

It is to be understood that the common layer may be a layer sharing warp threads with the first and second layers. Thus, in some embodiments the warp of the common layer is split between the first and second layers. It is to be understood therefore that the method includes the step of performing a transition whereby one layer of fabric transitions seamlessly to become a plurality of layers of fabric in a direction substantially parallel to the warp threads. It is to be understood that the common layer may be woven and the warp of the common layer subsequently split between the first and second layers and the first and second layers woven. Alternatively or in addition, the first and second layers may be woven and the warps of the first and second layers subsequently woven together by the common weft. The transition between weaving the common layer and weaving the double layer (constituted by the first and second layers) may be made so as to form a substantially seamless transition.

A transition from weaving a single layer to weaving a double layer may be made followed by a transition substantially seamlessly back to weaving a single layer. A tube of fabric a wall of which is provided by the first and second layers may thereby be fabricated. It is to be understood that the transition from the common layer to the first and second layers may be considered to be substantially seamless in some embodiments since a requirement to join the first and second layers in a post-weaving finishing operation may be eliminated.

It is to be understood that embodiments of the invention may be usefully applied in a range of different applications including the fabrication of garments such as T-shirts, shirts, trousers, blouses and the like where for example tubular portions can be fabricated for covering a torso, arm and/or leg. The tubular portions may be joined to form the garment in a single weaving operation. For example two tubular portions may be joined at a waist to form a pair of trousers.

The method may comprise joining the first and second layers by weaving the weft of each of the first and second layers with a common warp to form a common layer adjacent the first and second layers.

Thus it is to be understood that a transition from a common layer to first and second layers may be arranged to occur in a direction along the weft, substantially normal to the warp. It is to be understood that the warp of the common layer and the warp of each of the first and second layers may be substantially parallel.

Embodiments of the invention allow a substantially seamless transition from a single layer (the common layer) to a double layer (composed of the first and second layers) to be made in a direction across the warp. That is, one layer of fabric may transition substantially seamlessly to become a plurality of layers of fabric in a direction substantially perpendicular to the warp threads.

It is to be understood that a shape and orientation of a substantially seamless boundary between a single layer and a plurality of layers according to an embodiment of the invention may be formed to be of substantially any required shape or orientation. The boundary may for example form an angle to the warp at any suitable angle from 0° (being substantially parallel to the warp) and 90° (being substantially perpendicular to the warp) such as 30°, 45°, 60° or any other suitable angle. The boundary may be substantially straight, curved, for example in a circular, oval or elliptical manner, of a saw-tooth shape or any other required shape. By weaving in such a manner that a single layer becomes a plurality of layers along and across the warp threads, 'pockets' may be formed. The pockets may be formed that are suitable for making articles such as cushion covers, pillow cases, garments and the like with fewer or no post-weaving joining operations required compared with known methods of fabricating such articles.

The method may comprise forming the first and second layers whereby a common layer is provided that surrounds the first and second layers to form a pocket.

Multiple pockets may be formed along and/or across the warp. The pockets may be separated post-weaving by cutting, for example cutting through the common layer between pockets. Advantageously the method may comprise forming the first and/or second layer to have a free edge whereby an opening may be formed in the pocket.

This allows material such as padding to be inserted into the pocket, or an article such as a mobile telephone. It also allows the pocket to be turned inside out if required, for example to conceal any remaining portion of the common layer that may be present following separation of a pocket from one or more other pockets formed in the weaving operation.

As discussed above, tubes of fabric may be formed by weaving such that one layer of fabric becomes a double layer, and subsequently reverts to being a single layer. The transition may take place across the warp threads and/or along the warp threads, or at any chosen angle with respect to the warp threads. This may in some embodiments be performed multiple times in order to form a plurality of tubes. It is to be understood that cushion covers or other pockets may be formed by effecting a transition from single to double layer weaving both parallel to and perpendicular to the warp threads.

Other articles may be woven, such as garments. For example dresses, trousers, shirts, T-shirts, blouses and other garments may be woven. The garments may comprise multiple layers such as an outer layer and an inner layer such as a lining layer. An intermediate layer may be formed between the inner and outer layers, optionally a wadding layer. The wadding layer may comprise a weft and no warp. More than one inner layer and/or more than one outer layer may be provided. One or more pockets may be woven substantially seamlessly into a garment. For example a pocket may be defined by two outer layers, an interior being accessible from an outermost layer of the two, or by two inner layers, an interior being accessible from the innermost layer of the two.

It is to be understood that in some embodiments more than two layers of fabric may be woven substantially simultaneously and any one or more of those layers may become a plurality of layers along or across the warp threads as desired.

The method may comprise weaving in the same weaving operation a third layer, the third layer comprising a warp comprising warp threads and a weft comprising weft threads. The first and second layers may be joined along three edges to form a pocket having an opening along a fourth edge and the third layer may be arranged to overlie the opening.

The third layer may constitute a flap, and may be joined along three edges to the first and/or second layer, a middle of the three edges being the fourth edge. Thus the flap may be conveniently maintained in a substantially closed position in use.

Thus, this feature has the advantage that the third layer may be arranged to conceal the opening. In some embodiments the third layer may be arranged to prevent an article in the pocket from coming out of the pocket. For example in the case of a pillowcase or cushion cover the third layer (which as noted above may be in the form of a flap or like member) may prevent a padding material from falling out of the pillow or otherwise working its way out in use. In the case of a garment the third layer may prevent an article in the pocket from falling out, for example a wallet or mobile telephone.

The third layer may be joined to the first and/or second layers along one, two or three edges. Advantageously the method may comprise weaving at least a portion of the textile with a yarn comprising a heat activated adhesive. In other words, a yarn comprising a heat activated or temperature sensitive adhesive may be employed. This allows the formation of a hem by folding one or more layers of cloth and applying heat, for example by means of an iron. The temperature sensitive adhesive may be arranged to allow bonding of the portion having the temperature sensitive adhesive to another portion of the article when the adhesive is heated. The adhesive may be referred to as a heat activated or thermally activated adhesive.

This feature may be useful for example in the weaving of articles the size of which may require adaptation, such as curtains or garments. It is to be understood that embodiments of the invention may be advantageous in a number of applications.

For example, curtains may be woven with a tube at or near one end for receiving a curtain pole to enable hanging. In addition or instead, in some embodiments a yarn comprising a temperature sensitive adhesive may be employed, allowing the curtain to be cut to a required length and a hem formed by ironing rather than stitching.

In some embodiments a curtain having one or more outer layers and one or more inner lining layers may be woven, the one or more lining layers being woven such that they seamlessly join one or more outer layers to avoid a post-weaving joining operation. One or more lining layers may be arranged seamlessly to join one or more outer layers in a direction along a length of a curtain and/or across a width thereof.

The method may comprise weaving one or more cords through a portion of the textile to enable drawing of the textile.

The one or more cords may comprise a double braid.

Thus, in some embodiments, one or more cords may be woven through one or more layers of a textile in order to facilitate drawing in of the textile to create a ruched heading, for example in the case that curtains are being fabricated. An additional on or more cords may be woven in to the textile in some embodiments. In some embodiments this may provide hook anchors to facilitate attachment of hooks to the article, for example to enable hanging of curtains. Other ways of providing hook anchors are also useful. Advantageously the method may comprise forming a curtain in the single weaving operation, one of the first and second layers comprising a face fabric.

The method may comprise forming the curtain to further comprise a lining layer joined to the face fabric along at least one edge in the single weaving operation.

As noted aboce the method may comprise forming the curtain to have a substantially tubular portion in the single weaving operation, the tubular portion being arranged to allow a curtain pole to be passed therethrough to hang the curtain.

The method may comprise forming the curtain to comprise a draw thread or cord.

The method may comprise forming the hook anchors by threading cords through a layer of the curtain provided behind the face layer in the single weaving operation such that the hook anchor cords do not penetrate through the face layer.

It is to be understood that known curtains typically have three components: a face fabric, a lined fabric sewn to the face fabric, and a curtain tape sewn at the top of the curtain into which hooks are placed to hang the curtain. The tape may in some known arrangements be glued to the lining and/or a back of the face fabric by means of a heat sensitive adhesive (for example by ironing). A thread in the tape is drawn to create a ruched appearance at the head of the curtain. A tube may optionally be provided across the curtain, at or close to the top thereof to allow hanging from a pole that may be passed through the tube.

As described aboe, some embodiments of the present invention provide a curtain having a face fabric, optionally a lining fabric, a tubular curtain tape with draw thread and optionally hook anchors for attachment of hooks for hanging. The components are woven in combination together on a loom, eliminating the need for separate fabrication of the components and subsequent assembly of the components, for example by sewing or stitching together post-weaving. Other arrangements are also useful.

The method may comprise weaving at least a portion of the textile to comprise hook yarn and/or loop yarn to allow releasable joining of the textile. In an embodiment of the invention for which protection is sought there is provided a fabric having a hook or loop yarn woven therein, the fabric being provided with hooks or loops for fastening to corresponding complimentary loops or hooks. Thus, a requirement to attach to the fabric a tape having hook or loop yarn woven therein may be eliminated, since the hook or loop yarn is formed integrally with the fabric.

Further processing of the hook yarn may be required in some arrangements, for example cutting or other treatment of the yarn to form hooks, either during the weaving operation or in a post-weaving operation.

It is to be understood that articles having hook and/or loop yarn woven directly therein are able to be fabricated with a reduced amount of post-weaving processing such as article finishing processes. This provides an opportunity to reduce an overall cost of production of an article compared with traditional methods.

In some embodiments a textile is formed having a portion having hook yarn woven therein and a portion having loop yarn woven therein. In some embodiments, a length of an article woven from the fabric may be reduced if required by folding the article and coupling the portion having the hook yarn to the portion having the loop yarn.

In some embodiments the portions may be on the same side of the fabric. In some alternative embodiments the portions may be on opposite sides thereof. It is to be understood that such a fabric may be useful for making articles such as curtains or garments, which may be adjusted to a required length by means of the hook and loop fastenings. For example if a region of hooks and a region of loops are provided at respective locations on a curtain, the curtain may be folded and the regions of hooks and loops joined to one another.

The portions may be in the form of stripes or any other suitable shape or form.

In some embodiments a plurality of respective portions of one or both of loop yarn and hook yarn may be woven into a textile. In some embodiments this may allow a length of a finished article such as a curtain to be adjusted to one of a plurality of different lengths by folding the textile and coupling respective hook and loop portions to one another. In some embodiments alternate portions of hook yarn and loop yarn may be woven into the textile. Thus two or more repeat patterns of hook yarn portions and loop yarn portions may be woven into a textile.

In some embodiments, a textile may be woven as described above such that one layer of fabric transitions substantially seamlessly to a plurality of layers. Alternatively a plurality of layers may be woven with no transition to a lower or higher number of layers. During weaving, at least two of the plurality of layers may be woven such that each has at least one region of hook yarn or loop yarn woven therein such that each has a different one of the two yarns. In some embodiments this may allow a pocket formed by the woven textile to be opened and closed repeatedly along one or more sides, for example a pocket forming a cover such as a pillow case or cushion.

In some embodiments the portions of hook yarn and loop yarn may be woven into respective different layers of a textile or provided at respective different locations of the same layer. They may be arranged to allow releasable coupling of portions of a finished garment, such as an opening portion for example of a shirt, blouse, skirt, trousers or the like. In some embodiments a single layer of fabric may be provided with a portion of hook yarn woven therein and a portion of loop yarn woven therein, allowing article fabrication without a requirement to attach hook and loop tape.

In some embodiments an article such as a length of curtain may be woven having a face fabric layer and a lining fabric layer woven substantially simultaneously on the same loom, one or both layers each having a portion of hook yarn and a corresponding portion of loop yarn woven therein. This has the advantage that it may allow a length of the respective portions to be reduced by folding, such that the length of the face fabric and the length of the lining fabric may be reduced in a corresponding manner.

Other arrangements are also useful.

In some embodiments, a weave may be employed that places hooks or loops of the hook or loop yarn substantially on a single side of a fabric, for example a rear side or a front side. For example in some embodiments a twill such as a 3 in 1 twill or a satin or sateen may be woven and the yarn may be incorporated such that it is placed inside the fabric with the hooks or loops of the yarn provided at a rear face of the fabric and not a front face, or vice-versa. It is to be understood that embodiments of the present invention may also be applied in knitted materials as well as woven textiles. Thus, the present application may be read with reference to weaving replaced by reference to knitting. Thus, hook and loop yarn may be knitted into a knitted material in order to form a knitted article having hook and loop fastening functionality integrally formed therein during knitting. This has the advantage that a requirement to glue or sew hook and loop tape into the article in a post knitting finishing operation may be eliminated. The method may comprise forming the textile whereby at least the first layer comprises a phase change material.

The yarns that comprise the phase change material may be present in the weft of the first layer.

The yarns that comprise the phase change material may be present in the weft of the first layer in one selected from amongst an amount of between about 10 to 50% of the yarns, an amount of between about 20% and 40% of the yarns and an amount of about 30% of the yarns.

Optionally the remainder of the weft of the first layer comprises cotton yarn.

The phase change material may be operable to change phases at one selected from amongst between about 15 and 45°C, between about 20 and 40°C and at about 28 to 35°C.

The phase change material may be operable to change phases between the solid and the liquid phase at one selected from amongst between about 15 and 45°C, between about 20 and 40°C and at about 28 to 35°C.

The phase change material may comprise an organic phase change material, preferably paraffin wax.

The phase change material may be comprised in the first fabric in such a manner that the fabric is operable to withstand routine washing thereof without removal or substantial depletion of the phase change material. The yarns in the weft of the first layer may be spun yarns.

The method may comprise weaving the first layer whereby the warp thereof comprises polyester yarn.

The method may comprise forming the second layer to be substantially water resistant/repellent. The second layer may comprise a nano-chemical additive operable to render the second layer substantially water resistant/repellent.

It is to be understood that fluorocarbons may be employed to provide a water resistant textile, whilst silicone may be employed to provide a waterproof textile.

The nano-chemical additive may be orientated to fit into woven intersections of the second fabric material.

The nano-chemical additive may comprise a nano fluorocarbon chemical.

The method may comprise fixing the nano-chemical additive to the second fabric material by baking and/or irradiation by laser light.

The second layer may comprise a synthetic material, optionally more than 90% of a synthetic material, further optionally more than 95%.

The synthetic material may comprise a polyester material such as polyethylene terephthalate (PET). The second layer may comprise filament yarns, the yarns preferably comprising more than 100 filaments per yarn, more preferably more than 120 filaments per yarn and most preferably more than 130 filaments per yarn.

The filament yarns of the second layer preferably comprise less than 200 filaments per yarn, more preferably less than 180 filaments per yarn and most preferably less than 160 filaments per yarn. The yarns of the second layer may be filament yarns comprising between about 130 and 150 filaments per yarn. The yarns of the second layer may comprise about 140 filaments per yarn.

The yarns of the second layer may be filament yarns of substantially circular cross section. The method may comprise forming at least one of the first layer and the second layer to comprise indicia thereon.

The method may comprise weaving the indicia into the material during the single weaving operation.

Advantageously the method comprises carrying out the single weaving operation on a jacquard loom, optionally an electronically actuated jacquard loom.

In a further aspect of the invention for which protection is sought there is provided a textile comprising a first layer, the first layer comprising a warp comprising warp threads and a weft comprising weft threads, and a second layer, the second layer comprising at least a weft comprising weft threads, wherein the second layer and the first layer are formed to be integrally joined by weaving. The weft of the second layer may be woven with the warp of the first layer to join the layers.

Advantageously the weft of the second layer is woven with the warp of the first layer at a plurality of locations across the warp of the second layer.

The second layer may comprise a weft only and not a warp.

The first layer and second layer may be joined at locations defining a recurring pattern being one selected from amongst a diamond pattern, a square pattern, a rectangular pattern and a substantially circular pattern. The textile may comprise a third layer, the third layer comprising a warp comprising warp threads and a weft comprising weft threads.

The second layer may form an intermediate layer between the first layer and the third layer.

Advantageously the weft of the second layer is woven with the warp of the third layer at a plurality of locations across the weft of the second layer. The weft of the second layer may be woven with the warp of the first and third layers at substantially the same plurality of locations across the weft of the second layer.

Advantageously the weft of the second layer comprises a wadding yarn. The wadding yarn may comprise one or more stretch fibres.

The wadding yarn may be a filament yarn or a spun yarn.

The second layer may comprise a warp, the warp comprising warp threads and a weft, the weft comprising weft threads.

The first and second layers may be joined by weaving of the warp of the first and second layers with a common weft to form a common layer. The first and second layers may be joined by weaving the weft of each of the first and second layers with a common warp to form a common layer. The common layer may lie substantially adjacent an edge of the first and second layers, the edge being defined by a boundary at which the first and second layers merge with the common layer.

Advantageously the common layer surrounds the first and second layers on at least three sides to form a pocket.

The textile may be formed wherein first and/or second layer has a free edge wherein an opening is formed in the pocket. In a further aspect of the invention for which protection is sought there is provided a garment comprising a textile according to the preceding aspect.

In a still further aspect of the invention for which protection is sought there is provided a cushion cover or pillow case comprising a textile according to a preceding aspect.

In an aspect of the invention for which protection is sought there is provided a curtain comprising a textile according to the preceding aspect. In one aspect of the invention for which protection is sought there is provided a weaving loom configured to implement a method according to a preceding aspect.

In an aspect of the invention for which protection is sought there is provided a textile material comprising: a first layer, comprising a first fabric; a second layer, comprising a second fabric; and an intermediate layer, the intermediate layer comprising a wadding material and being arranged generally between the first layer and the second layer; wherein the first layer, second layer and intermediate layer are woven together in a single weaving operation. In one aspect of the invention for which protection is sought there is provided a method of forming a textile material, the method comprising weaving together, in a single weaving operation, a first layer, comprising a first fabric, a second layer, comprising a second fabric and an intermediate layer, the intermediate layer comprising a wadding material and being arranged generally between the first layer and the second layer.

Optionally, the method may comprise forming the textile whereby at least the first layer comprises a phase change material. Further optionally, the method comprises carrying out the single weaving operation on a jacquard loom. Advantageously, the jacquard loom may be an electronically actuated jacquard loom.

Further advantageously the method may comprise weaving the first layer whereby the first layer comprises a warp and a weft. The yarns that comprise the phase change material may be present in the weft of the first layer, preferably in an amount of between about 10 to 50%, more preferably between about 20% and 40% and most preferably about 30%. The remainder of the weft of the first layer may comprise cotton yarn. The yarns in the weft of the first layer may be spun yarns.

The method may comprise weaving the first layer whereby the warp thereof comprises polyester yarn. The phase change material may be operable to change phases at between about 15 and 45°C, more preferably between about 20 and 40°C and most preferably at about 28 to 35°C. It is to be understood that the material may be operable to change phase to the liquid phase at a temperature at or below a temperature of the human body. Preferably, the phase change material is operable to change phases between the solid and the liquid phase at between about 15 and 45°C, more preferably between about 20 and 40°C and most preferably at about 28 to 35°C.

Preferably, the phase change material comprises an organic phase change material, preferably paraffin wax.

Preferably, the phase change material is comprised in the first fabric in such a manner, that the fabric is operable to withstand routine washing thereof without removal or substantial depletion of the phase change material.

The method may comprise weaving the second layer. The second layer may be substantially water resistant/repellent. In one embodiment, the second layer may comprise a nano-chemical additive that preferably is operable to render the second layer substantially water resistant/repellent. The nano-chemical additive is preferably orientated to fit into woven intersections of the second fabric material. Suitable nano- chemical additives include a nano fluorocarbon chemical that preferably is baked onto the fabric and preferably operable to make the fabric durable, water and/or soil resistant and/or breathable. In one embodiment, the nano-chemical additive is applied to the second fabric by laser. The second layer is preferably formed from more than 90% of a synthetic material, preferably more than 95%. The synthetic material may comprise a polyester material such as polyethylene terephthalate (PET), for example. Preferably, the yarns of the second layer are filament yarns, which preferably comprise more than 100 filaments per yarn, more preferably more than 120 filaments per yarn and most preferably more than 130 filaments per yarn.

Preferably, the yarns of the second layer are filament yarns, which preferably comprise less than 200 filaments per yarn, more preferably less than 180 filaments per yarn and most preferably less than 160 filaments per yarn.

In a most preferred embodiment, the yarns of the second layer are filament yarns, which preferably comprise between about 130 and 150 filaments per yarn. In a particularly preferred embodiment the yarns of the second layer comprise about 140 filaments per yarn.

Preferably, the filament yarns of the second layer have a generally circular cross section.

The intermediate layer comprises a wadding material, which preferably comprises a plurality of yarns.. The plurality of yarns are preferably arranged in the weft. The intermediate layer preferably comprises a weft, but no warp. The plurality of yarns are preferably stretch fibres.

Preferably, the yarns of the wadding material are filament yarns, preferably comprising more than 50 filaments per yarn, more preferably more than 60 filaments per yarn. Preferably, the yarns of the wadding material are filament yarns comprising less than 100 filaments per yarn, more preferably less than 90 filaments per yarn.

In a most preferred embodiment, the yarns of the wadding material are filament yarns which preferably comprise between about 70 and 80 filaments per yarn, such as, for example, 72 filaments per yarn. Preferably, at least one of the first layer or the second layer comprises indicia thereon, which indicia may be applied by being woven into the material The first layer, intermediate layer and second layer are preferably held together by stitching. The first layer, second layer and intermediate layer are preferably held together by stitching , which may be arranged in a recurring diamond pattern, for example.

The term "phase change material" as used herein refers to a substance wherein heat is absorbed or released when the material changes phases, preferably from solid to liquid and vice versa.

According to an aspect of the present invention for which protection is sought there is provided a textile material comprising:

a first layer, comprising a first fabric;

a second layer, comprising a second fabric; and

an intermediate layer, the intermediate layer comprising a wadding material and being arranged generally between the first layer and the second layer;

wherein at least the first layer comprises a phase change material. Preferably, the first layer, second layer and intermediate layer are woven together, preferably in a single weaving process.

Preferably, the single weaving operation is carried out on a jacquard loom. Preferably, the jacquard loom is an electronically actuated jacquard loom.

Preferably, the first layer comprises a warp and a weft.

The yarns that comprise a phase change material are preferably present in the weft of the first layer, preferably in an amount of between about 10 to 50%, more preferably between about 20% and 40% and most preferably about 30%. Preferably, the remainder of the weft of the first layer comprises cotton yarn. Preferably, the yarns in the weft of the first layer are spun yarns.

Preferably, the warp of the first layer comprises polyester yarn. Preferably, the phase change material is operable to change phases at between about 15 and 45°C, more preferably between about 20 and 40°C and most preferably at about 28 to 35°C. Preferably, the phase change material is operable to change phases between the solid and the liquid phase at between about 15 and 45°C, more preferably between about 20 and 40°C and most preferably at about 28 to 35°C.

Preferably, the phase change material comprises an organic phase change material, preferably paraffin wax.

Preferably, the phase change material is comprised in the first fabric in such a manner, that the fabric is operable to withstand routine washing thereof without removal or substantial depletion of the phase change material.

The second layer is preferably woven. The second layer may be substantially water resistant/repellent. In one embodiment, the second layer may comprise a nano- chemical additive that preferably is operable to render the second layer substantially water resistant/repellent. The nano-chemical additive is preferably orientated to fit into woven intersections of the second fabric material. Suitable nano-chemical additives include: a nano fluorocarbon chemical that preferably is baked onto the fabric and preferably operable to make the fabric durable, water and/or soil resistant and/or breathable. In one embodiment, the nano-chemical additive could be applied to the second fabric by laser.

The second layer is preferably formed from more than 90% of a synthetic material, preferably more than 95%. The synthetic material may comprise a polyester material such as polyethylene terephthalate (PET), for example. Preferably, the yarns of the second layer are filament yarns, which preferably comprise more than 100 filaments per yarn, more preferably more than 120 filaments per yarn and most preferably more than 130 filaments per yarn.

Preferably, the yarns of the second layer are filament yarns, which preferably comprise less than 200 filaments per yarn, more preferably less than 180 filaments per yarn and most preferably less than 160 filaments per yarn. In a most preferred embodiment, the yarns of the second layer are filament yarns, which preferably comprise between about 130 and 150 filaments per yarn. In a particularly preferred embodiment the yarns of the second layer comprise about 140 filaments per yarn.

Preferably, the filament yarns of the second layer have a generally circular cross section. The intermediate layer comprises a wadding material, which preferably comprises a plurality of yarns.. The plurality of yarns are preferably arranged in the weft. The intermediate layer preferably comprises a weft, but no warp. The plurality of yarns are preferably stretch fibres. Preferably, the yarns of the wadding material are filament yarns, preferably comprising more than 50 filaments per yarn, more preferably more than 60 filaments per yarn. Preferably, the yarns of the wadding material are filament yarns comprising less than 100 filaments per yarn, more preferably less than 90 filaments per yarn. In a most preferred embodiment, the yarns of the wadding material are filament yarns which preferably comprise between about 70 and 80 filaments per yarn. Such as, for example, 72 filaments per yarn.

Preferably, at least one of the first layer or the second layer comprises indicia thereon, which indicia may be applied by being woven into the material

The first layer, intermediate layer and second layer are preferably held together by stitching. The first layer, second layer and intermediate layer are preferably held together by stitching, which may be arranged in a recurring diamond pattern, for example.

The term "phase change material" as used herein refers to a substance wherein heat is absorbed or released when the material changes phases, preferably from solid to liquid and vice versa. According to a further aspect of the present invention there is provided a method of forming a textile material, the method comprising weaving together, in a single weaving operation, a first layer, comprising a first fabric, a second layer, comprising a second fabric and an intermediate layer, the intermediate layer comprising a wadding material and being arranged generally between the first layer and the second layer, wherein at least the first layer comprises a phase change material.

According to a yet further aspect of the present invention, there is provided a garment comprising a textile material according to any preceding aspect.

Preferably, an outermost layer of the textile material in the garment, in use, is the second layer.

In a further aspect of the invention for which protection is sought there is provided a method of forming a textile material, the method comprising weaving together, in a single weaving operation, a first layer, comprising a warp and a weft, and a wadding layer comprising a weft comprising wadding material, the method comprising joining the wadding layer and the first layer along a seam during the weaving operation whereby a weft of the wadding layer is interwoven with a warp of the first layer.

The wadding layer may comprise only a weft. Alternatively the wadding layer may comprise a warp and a weft.

Advantageously the method may comprise weaving, in the single weaving operation, a second layer.

The second layer may be woven whereby the wadding layer forms an intermediate layer between the first layer and the second layer. The method may comprise forming the textile whereby at least the first layer comprises a phase change material.

In one aspect of the invention for which protection is sought there is provided a method of weaving an article comprising the steps of:

weaving a length of fabric extending in a direction along an array of warp threads; and performing a transition whereby one layer of fabric transitions substantially seamlessly to become a plurality of layers of fabric as the article is woven.

It is to be understood that when fabricating certain articles such as cushion covers, pillow cases, garments and the like, one or more joining operations are required in which two or more layers of fabric are joined together. Embodiments of the present invention have the advantage that one of more of these joining operations may be eliminated by suitable control of a loom when weaving an article. This is because the loom may be operated in such a manner that a substantially seamless transition may be made from the weaving of a single layer to the weaving of two or more layers.

It is to be understood that in order to effect the transition from the weaving of one layer to the weaving of two or more layers from that one layer, careful control of the shedding and picking processes may be required.

It is to be understood that each pick of a weft transit device results in a weft thread traversing one layer of fabric. The weft transit device may be a shuttle, a rapier or any other suitable device. In some embodiments, in order for the weft transit device to traverse two layers of the two or more further layers, at least two picking operations may be required.

For example, if (say) a double layer of fabric is to be made, of a plain weave, the number of warp threads per layer of fabric might be arranged to be substantially equal for each layer. Thus, in some embodiments adjacent warp threads may be arranged to belong to a different one of the two layers when the two layers are being woven. Of the warp threads forming a given layer, every other one of these warp threads may be raised and a pick operation performed before these warp threads are lowered. The remaining warp threads of that layer may then be raised and a further pick operation performed.

The same process may then be repeated for the warp threads forming the other layer.

It is to be understood that other sequences of raising and lowering of warp threads may be performed, particularly where more complex weaves may be desirable. It is to be further understood that the ability to realise the present invention has come with the development of computer controlled looms allowing highly sophisticated weaving operations to be performed. A variety of different weave types may be created in multiple layers with a suitable sequence of raising and lowering of each warp thread and picking of the weft transit device.

Optionally, the method may include the step of performing a transition whereby one layer of fabric transitions seamlessly to become a plurality of layers of fabric in a direction substantially perpendicular to the warp threads.

Alternatively or in addition, the method may include the step of performing a transition whereby one layer of fabric transitions seamlessly to become a plurality of layers of fabric in a direction substantially parallel to the warp threads. It is to be understood that a shape and orientation of a boundary between a single and a plurality of layers may be formed to be any required shape or orientation. The transition may for example take place along a line that forms an angle to the warp at any suitable angle from substantially 0° (being substantially parallel to the warp) to substantially 90° (being substantially perpendicular to the warp). The boundary may be substantially straight, curved or of any other suitable shape such as a saw-toothed shape or any required shape.

By weaving in such a manner that a single layer becomes a plurality of layers along and across the warp threads, 'pockets' may be formed. The pockets may be formed in such a manner that the textile is suitable for making articles such as cushion covers, pillow cases, garments and the like with fewer or no post-weaving joining operations required compared with known methods of fabricating such articles.

Tubes of fabric may be formed, by weaving such that one layer of fabric becomes a double layer, and subsequently reverts to being a single layer. The transition may take place across the warp threads or along the warp threads, or at any chosen angle with respect to the warp threads. This may in some embodiments be performed multiple times in order to form a plurality of tubes. It is to be understood that cushion covers or other pockets may be formed by effecting a transition from single to double layer weaving both parallel to and perpendicular to the warp threads. Complex articles such as garments having one or more sleeves may be fabricated in a single weaving operation, optionally substantially entirely in a single weaving operation.

For example, across a warp or along the warp multiple tubular forms may be fabricated, a first for a first sleeve, a second for a torso, a third for a second sleeve. The tubes may be joined substantially seamlessly. Common, single layers between the respective sleeves and torso portions may be cut and the article turned inside out to form a substantially seamless garment. Other arrangements are also useful. It is to be understood that in some embodiments more than two layers of fabric may be woven substantially simultaneously and any one or more of those layers may become a plurality of layers along or across the warp threads as desired.

In one embodiment, a portion of an article may be woven with a yarn comprising a temperature sensitive adhesive. This allows the formation of a hem by folding one or more layers of cloth and applying heat, for example by means of an iron. The temperature sensitive adhesive may be arranged to allow bonding of the portion having the temperature sensitive adhesive to another portion of the article when the adhesive is heated. The adhesive may also be referred to as a heat activated or thermally activated adhesive.

This feature may be useful for example in the weaving of articles the size of which may require adaptation, such as curtains or garments. It is to be understood that embodiments of the invention may be advantageous in a number of applications.

For example, curtains may be woven with a tube at or near one end for receiving a curtain pole to enable hanging. In some embodiments a yarn comprising a temperature sensitive adhesive may be employed, allowing the curtain to be cut to a required length and a hem formed by ironing rather than stitching.

In some embodiments a curtain having one or more outer layers and one or more inner lining layers may be woven, the one or more lining layers being woven such that they seamlessly join one or more outer layers to avoid a post-weaving joining operation. One or more lining layers may be arranged seamlessly to join one or more outer layers in a direction along a length of a curtain and/or across a width thereof. In some embodiments, a double braid may be woven through one or more layers of a textile in order to facilitate drawing in of the textile to create a ruched heading, for example in the case that curtains are being fabricated. An additional double braid may be woven in to the textile in some embodiments. In some embodiments this may facilitate attachment of hooks to the article, for example to enable hanging of curtains. Embodiments having one or more double braids woven therein may be single layer or multiple layer textiles.

It is to be understood that known curtains typically have three components: a face fabric, a lined fabric sewn to the face fabric, and a curtain tape sewn at the top of the curtain into which hooks are placed to hang the curtain. The tape may in some known arrangements be glued to the lining and/or a back of the face fabric by means of a heat sensitive adhesive (for example by ironing). A thread in the tape is drawn to create a ruched appearance at the head of the curtain. As noted above, a tube may optionally be formed across the curtain at or close to the top thereof to allow hanging from a pole that may be passed through the tube.

Some embodiments of the present invention provide a curtain having a face fabric, optionally a lining fabric, a tubular curtain tape with draw thread and optionally hook anchors for attachment of hooks for hanging. The components are woven in combination together on a loom, eliminating the need for separate fabrication of the components and subsequent assembly of the components, for example by sewing or stitching together post-weaving. Other arrangements are also useful. In an embodiment of the invention for which protection is sought there is provided a fabric having a hook or loop yarn woven therein, the fabric being provided with hooks or loops for fastening to corresponding complimentary loops or hooks. Thus, a requirement to attach to the fabric a tape having hook or loop yarn woven therein may be eliminated, since the hook or loop yarn is formed integrally with the fabric.

It is to be understood that articles having hook and/or loop yarn woven directly therein are able to be fabricated with a reduced amount of post-weaving processing such as finishing processes. This provides an opportunity to reduce an overall cost of production of an article compared with traditional methods. In some embodiments a portion having hook yarn woven therein and a portion having loop yarn woven therein is provided. Thus, a length of an article woven from the fabric may be reduced if required by folding the article and coupling the portion having the hook yarn to the portion having the loop yarn. In some embodiments the portions may be on the same side of the fabric. In some alternative embodiments the portions may be on opposite sides. It is to be understood that such a fabric may be useful in fabricating articles such as curtains or garments, which may be adjusted to a required length by means of the hook and loop fastenings. The portions may be in the form of stripes or any other suitable shape or form.

In some embodiments a plurality of respective portions of one or both of loop yarn and hook yarn may be woven into a textile. In some embodiments this may allow a length of a finished article such as a curtain to be adjusted to one of a plurality of different lengths by folding the textile and coupling respective hook and loop portions to one another. In some embodiments alternate portions of hook yarn and loop yarn may be woven into the textile. Thus two or more repeat patterns of hook yarn portions and loop yarn portions may be woven into a textile. In some embodiments, a textile may be woven as described above such that one layer of fabric transitions substantially seamlessly to a plurality of layers. Alternatively a plurality of layers may be woven with no transition to a lower or higher number of layers. During weaving, at least two of the plurality of layers may be woven such that each has at least one region of hook yarn or loop yarn woven therein such that each has a different one of the two yarns. In some embodiments this may allow a pocket formed by the woven textile to be opened and closed repeatedly along one or more sides, for example a pocket forming a cover such as a pillow case or cushion.

In some embodiments the portions of hook yarn and loop yarn may be woven into respective different layers of a textile or provided at respective different locations of the same layer. They may be arranged to allow releasable coupling of portions of a finished garment, such as an opening portion for example of a shirt, blouse, skirt, trousers or the like. In some embodiments a single layer of fabric may be provided with a portion of hook yarn woven therein and a portion of loop yarn woven therein, allowing article fabrication without a requirement to attach hook and loop tape. In some embodiments an article such as a length of curtain may be woven having a face fabric layer and a lining fabric layer woven substantially simultaneously on the same loom, one or both layers each having a portion of hook yarn and a corresponding portion of loop yarn woven therein. This has the advantage that it may allow a length of the respective portions to be reduced by folding, such that the length of the face fabric and the length of the lining fabric may be reduced in a corresponding manner.

Other arrangements are also useful.

In some embodiments, a weave may be employed that places hooks or loops of the hook or loop yarn substantially on a single side of a fabric, for example a rear side or a front side. For example if a 3 in 1 twill or a satin or sateen is woven the yarn may be incorporated such that it is placed inside the fabric with the hooks or loops of the yarn provided at a rear face of the fabric and not a front face, or vice-versa.

It is to be understood that embodiments of the present invention may also be applied in knitted materials as well as woven textiles. Thus, the present application may be read with reference to weaving replaced by reference to knitting. Thus, hook and loop yarn may be knitted into a knitted material in order to form a knitted article having hook and loop fastening functionality integrally formed therein during knitting. This has the advantage that a requirement to glue or sew hook and loop tape into the article in a post knitting finishing operation may be eliminated. It is to be understood that textiles according to embodiments of the present invention and articles formed from the textiles may be coloured post-weaving and/or woven from coloured yarns or other threads.

In some embodiments the textiles are piece dyed after weaving. In the case that an article comprises polyester and cotton, selected dyestuffs may be employed to dye the polyester and the cotton different respective colours in a single bath of dyestuff.

Typically, the required dyestuffs are placed in a bath with the textile to be dyed and the dyestuff heated.. It is to be understood that the dyestuffs for dyeing the polyester and the dyestuffs for dyeing the cotton are activated at different temperatures and dye only the respective polyester or cotton material. This enables the respective materials to be dyed different respective colours in a single bath post-weaving. All of the features disclosed herein may be combined with any of the above aspects and in any combination. BRIEF DESCRIPTION OF THE DRAWINGS

For a better understanding of the invention, and to show how embodiments of the same may be carried into effect, reference will now be made, by way of example, to the accompanying diagrammatic drawings in which:

FIGURE 1 shows an exploded view of a textile material according to the invention;

FIGURE 2 shows a perspective view of a textile material according to the invention; and

FIGURE 3 shows (a) a side view of a loom suitable for forming a textile according to an embodiment of the invention and (b) a cross-sectional view of an arrangement of inner, intermediate and outer layers during the weaving thereof. FIGURE 4 is a schematic plan view illustration of a length of textile according to an embodiment of the present invention;

FIGURE 5 is a cross-sectional view of a pocket of the textile of FIG. 1 viewed in a direction perpendicular to warp threads of the pocket;

FIGURE 6 is a schematic plan view illustration of a length of textile according to a further embodiment of the present invention;

FIGURE 7 is a cross-sectional view of a pocket formed from the textile of FIG. 3 viewed in a direction perpendicular to warp threads of the pocket;

FIGURE 8 is a draft and peg plan for forming a pocket according to an embodiment of the present invention; FIGURE 9 shows (a) a plan view of a length of face fabric of a curtain according to an embodiment of the invention and (b) a cross-sectional view of a portion of the fabric shown in (a) after cutting along line A-A and folding the fabric to couple respective stripes of hook and loop yarn to be coupled to one another;

FIGURE 10 shows a plan view of a fabric according to a further embodiment of the invention; and

FIGURE 1 1 shows a plan view of a textile as produce on a loom in which a T-shirt has been woven. Referring firstly to FIG. 1 , there is shown an exploded view of a textile material 102 according to an embodiment of the present invention. The textile material 102 is formed from three layers, being an inner layer 104, which comprises a phase change material, an intermediate layer 106 formed from a wadding material and an outer layer 108 formed from a waterproof material.

In more detail, the inner layer 104 comprises yarns having a micro composite phase change material (paraffin based) woven into the weft thereof therein. Accordingly, the weft of the inner layer 104 comprises 30% phase change material and 70% cotton. In the present example, the fibres having paraffin microparticles embedded therein are Smartcel™ Clima, commercially available from Smartfiber A.G. The paraffin used in these fibres has a solid/liquid phase transition temperature of about 28 to 35°C.

The warp of the inner layer comprises polyester yarns although other yarns are also useful.

The intermediate layer 106 is formed from a plurality of filament yarns having 72 filaments per yarn. Again, other yarns are also useful. These yarns are formed from 100% high stretch polyester. The count of the yarn is 4/167/72 dt. The intermediate layer is formed of weft only,

The outer layer 108 is formed from a woven fibre comprising yarns of polyethylene terephthalate (PET). Other materials are also useful. These yarns are filament yarns and have 140 filaments per yarn. The filament yarn is generally circular in cross section. The outer layer 108 comprises a nano-chemical finish to enable it to resist soiling and water, yet remain breathable. The nano-chemicals comprise nano fluorocarbon chemicals applied and baked after the fabrics is woven, which operate at a molecular level by fitting into the woven intersections of the fabric.

In the embodiment shown in FIG. 2, the inner layer 104, intermediate layer 106 and outer layer 108 are held together by stitching 1 10 in a diamond pattern as shown in FIG. 2. The outer layer 108 is shown having a logo 1 12 woven into the fabric of the outer layer 108. The stitching 1 10 is formed as part of the weaving operation and is formed by weaving the weft of the intermediate layer 106 with the warp of the inner layer 104. In some alternative embodiments the weft of the intermediate layer 106 is instead woven with the warp of the outer layer 108. In some still further embodiments the weft of the intermediate layer 106 is woven with the warp of both the inner and outer layers 104, 108. The weft of the intermediate layer 106 may be woven with the warp of the inner and outer layers 104, 108 at substantially the same or different respective locations across the respective warps.

A textile material 102 made in accordance with the above described embodiment has utility in a number of situations, but particularly in outer clothing. This is because the phase change material in the inner layer 104 is an excellent temperature regulator, thereby ensuring that the wearer of the garment does not get too hot or too cold in extremes of ambient temperatures. Furthermore, the intermediate layer 106 of wadding gives a quilted look to the fabric, which is visually attractive and also provides an insulation layer to the fabric. Finally, the outer layer 108 is water proof, yet breathable, thereby ensuring that a user is kept dry, but enabling air flow through the fabric to allow enhanced comfort of the wearer of the garment. The outer layer 108 also has a logo woven in to the fabric to thereby provide an opportunity for the provider of the fabric to indicate trade origin and/or for decorative purposes, depending on requirements.

In one embodiment, the textile material may be used in curtains. In such an embodiment, the textile material might not comprise the non-chemicals on the outer layer, since it might not be desired to make them waterproof. Nevertheless, the phase change material enables the curtains to maintain a steady temperature in the room in which they are hung. As stated above, the textile material 102 is formed by weaving the three layers 104, 106, 108 in a single weaving operation. It is to be understood that in a weaving operation a weft transit device such as a shuttle, a rapier or any other suitable device moves to and fro across warp threads which are raised and lowered in sequence to form the desired textile material. FIG. 3(a) is a schematic illustration of a weaving loom 150 suitable for fabricating textile materials according to embodiments of the present invention including the textile material 102 shown in FIG. 1 . The loom 150 is arranged to receive a row of warp threads WP from a corresponding row of respective bobbins WPB. The warp threads WP pass out from the loom 150 on an opposite side thereof to the bobbins WPB.

The warp threads WP are coupled to a harness that allows the threads to be raised or lowered. The loom 150 of FIG. 1 is an electronically controlled loom, allowing each warp thread WP to be raised or lowered individually and independently of any other warp thread WP.

The loom 150 is operable to fire a weft transit device 152 from side to side across the warp threads WP, the device 152 passing either above or below each warp thread WP as it does so.

When forming a single layered fabric, each of the warp threads WP is incorporated into the single layer of fabric.

When weaving two or more layers substantially simultaneously, the warp threads are arranged to be divided between the two or more layers, optionally substantially equally. The warp threads are raised or lowered as required and the weft transit device 152 is fired from one side to the other. This is referred to as a 'pick' of the weft transit device 152. Each pick of the device 152 results in a weft thread traversing one layer of fabric. In some weaving operations the device 152 may be arranged to traverse a different layer on successive picks for at least part of the weaving operation, forming a weft thread in a different layer during each successive pick. In addition or instead, in some weaving operations the device 152 may be arranged to traverse the same layer a plurality of successive times before traversing another layer, for at least part of the weaving operation. It is to be understood that, in order for the weft transit device to traverse two layers of the fabric, at least two picking operations will typically be required.

In the present example the intermediate wadding layer 106 is arranged not to comprise any warp threads WP. Accordingly the warp threads WP are confined to the inner and outer layers 104, 108. However, the weft of the wadding layer 106 is woven with warp threads WP of the inner layer 104 at periodic intervals across the warp WP to prevent sag of the weft of the wadding layer 106 as shown in FIG. 3 (b). It is to be understood that the weft of the wadding layer 106 is advantageously woven with warp threads WP at intervals rather than continuously in order to allow the yarn of the wadding layer to remain air filled, in some embodiments. If the wadding yarn is compressed between warp threads, an amount of thermal insulation provided by the wadding layer 106 is reduced. As noted above, stitching of the weft of the wadding layer 106 to the warp of the inner and/or outer layers 104, 108 reduces sag of the weft and allows the wadding layer 106 to be more uniformly distributed between the inner and outer layers 104, 108.

If the inner and outer layers 104, 108 are to be made of a plain weave, the number of warp threads per layer of fabric may be arranged in some embodiments to be substantially equal for each layer 104, 108. In some embodiments adjacent warp threads WP of the loom 150 may be arranged to belong to a different one of the two layers 104, 108 although other arrangements are also useful. Of the warp threads WP forming a given layer 104, 108, in some embodiments every other one of these warp threads WP may be raised and a pick operation performed before these warp threads WP are lowered. The remaining warp threads WP of that layer may subsequently be raised and a further pick operation performed. Again, other arrangements are also useful. For example pick operations may alternate between the first, second and third layers.

The same process may then be repeated for the warp threads WP forming the other layer.

It is to be understood that other sequences of raising and lowering of warp threads may be performed, particularly where more complex weaves may be desirable. It is to be further understood that the ability to realise the present invention has come with the development of computer controlled looms allowing highly sophisticated weaving operations to be performed. A variety of different weave types may be created in multiple layers with a suitable sequence of raising and lowering of each warp thread and picking of one or more weft transit devices 152.

As described above, the intermediate layer 106 of the textile material 102 is formed from weft threads only. The inner and outer layers 104, 108 are formed from respective warp threads and corresponding weft threads. FIG. 3(b) shows a snapshot of a portion of a weaving operation in cross-section. At the instant shown, the weft transit device 152 is transiting the warp threads 104WP of the inner layer 104. Alternate warp threads WP of the inner layer 104 have been raised with respect to adjacent warp threads WP of the inner layer 104. The transit device 152 is shown in a process of moving across the loom 150 from left to right between adjacent warp threads WP.

Once a given pick operation is complete, alternate warp threads may be raised and lowered and a further pick operation performed in the same layer 104. Alternatively, a pick operation may be performed between alternate warp threads 108WP of the outer layer 108. Alternatively or in addition a pick operation may be performed between the inner and outer layers 104, 108 in order to form the intermediate wadding layer 106. Weft threads of the wadding layer 106 are shown at 106WT in FIG. 3(b).

As noted above, a given pick operation need not necessarily involve the weft transit device 152 traversing between adjacent warp threads WP, this example being given by way of illustration only. The weft transit device 152 may be passed between warp threads that are raised and lowered according to an operator's requirement. Thus in some arrangements every third, fourth, fifth or further warp thread WP may be raised or lowered as required and a pick operation performed. Raising or lowering of warp threads WP need not be periodic across a given layer, but may be set to any desired arrangement.

It is to be understood that a plurality of weft transit devices 152 may be available, and one or more devices 152 may traverse the warp threads WP of a layer 104, 108 in a given picking operation. The devices may carry threads of different colours and/or types. One thread may be coated, impregnated or otherwise provided with a phase change material. One thread may be a thread suitable for forming a wadding layer.

In the present embodiment the intermediate layer 106 does not contain any warp threads WP. Accordingly, as discussed above the weft transit device 152 carrying a weft thread 106WT from which the intermediate layer 106 is formed may be fired across the loom 150 between respective sets of warps of the inner and outer layers 104, 108 in order to form the intermediate layer 106. FIG. 4 shows a textile 101 of length L that has been woven in such a manner as to form an enclosed pocket 1 10. The pocket is suitable for containing a filling or padding to form a cushion cover, pillow case or the like.

The textile 101 shown has a width from left to right in FIG. 4 of 237cm although other widths are also useful. The textile has been woven in such a manner that the number of layers of fabric forming the textile varies substantially seamlessly across the width of the textile, i.e. across the warp threads, and along the length of the textile, parallel to the warp threads. By seamless is meant that layers or free ends or edges of material are not joined by way of a joining operation post weaving. Rather, the layers are formed together during the weaving of the textile 101 such that a post-weaving joining operation is not required to be performed.

In regions 101A of the textile 101 the textile 101 has one layer. In regions 101 B the textile has two layers and in regions 101 C the textile has three layers. Dotted lines 103 illustrate a boundary of each pocket 1 10 between the pocket 1 10 (which has two layer or three layer regions 101 B, 101 C) and the single-layered regions 101 A between pockets 1 10. Thus in the embodiment of FIG. 1 the boundary 103 defines a location at which a transition to a single layered textile takes place. Boundary 105 defines a free edge of a third layer of the pocket 1 10, being the boundary between two layered region 101 B and three layered region 101 C of the textile 101.

It is to be understood that, in FIG. 4, along line X-X the number of layers of fabric alternates between one and two across a width of the textile 101 . Along line Y-Y the number of layers alternates between one and three across the width of the textile 101 in a corresponding manner. Along line Z-Z the number of layers remains equal to one across the width of the textile 101. It is to be understood that by cutting through regions 101 A at or close to the border with regions 101 B and 101 C, the pockets 1 10 may be separated. The pockets 1 10 may be used in the configuration as woven, or turned inside out to hide the single layer regions that formerly separated the pockets 1 10 from one another.

FIG. 5 shows a pocket 1 10 in cross-section as viewed in a direction perpendicular to the warp threads. It can be seen that in the example shown a first layer of fabric 107F forms a front layer of the pocket 1 10, a second layer 107R forms a rear layer and a third layer 107FL forms a flap layer behind the second layer 107R that helps to prevent padding from falling out of the pocket 1 10. It is to be understood that the front and rear layers 107F, 107R are joined along a basal edge 103B and side edges 103S (shown dotted) of the pocket 1 10. The front and flap layers 107F, 107FL are joined along a head edge 103H opposite the basal edge 103B and along side edges of the flap layer 107FL. Arrow P shows a path along which padding may be inserted into the pocket 1 10. The pocket 1 10 is shown prior to being turned inside out, if required.

FIG. 6 shows a length L of textile 201 according to a further embodiment of the invention. Like features of the embodiment of FIG. 5 to those of the embodiment of FIG. 4 are shown with like reference signs prefixed numeral 2 instead of numeral 1 . The textile 201 has been woven to form pockets 210 similar to those of the embodiment of FIG. 4 except that the third layer 107FL has been omitted. Instead of forming a flap layer 107FL overlying front and rear layers, a flap portion 207FL (FIG. 4) is provided by extension of front layer 207F beyond a boundary of rear layer 207R. The flap portion is formed by region 201 A of the textile 101 (FIG. 6). Thus the front and rear layers are not substantially coextensive, the front layer 207F extending beyond a border of the rear layer 207R in one direction. In the embodiment of FIG. 4 the front and rear layers 107F, 107R are substantially coextensive. The flap 207FL is arranged to be folded back and tucked between the front and rear layers 207F, 207R in order to prevent padding from falling from inside the pocket 210. It is to be understood that pocket 210 shown in FIG. 7 may be turned inside out in order to hide any portions of the single layer 201A that might otherwise be visible. Edge 205 shown in FIG. 6 and FIG. 7 is a free edge of rear layer 207R. In one embodiment the pocket 210 may be arranged to be around 10 inches square with a 6 inch flap extending laterally from the opening between front and rear layers. Other dimensions are also useful. FIG. 8 shows a draft and peg plan for a cushion cover according to an embodiment of the present invention, implemented using eight shafts. Other numbers of shafts are also useful and embodiments of the invention are not limited to eight shafts.

In the plan, solid or shaded squares in the columns indicated 'R' are coloured red, those in columns 'B' are blue, those in columns Ύ' are yellow and those in columns 'G' are green. The arrangement of columns R, B, Y, G repeats periodically across the figure. Solid squares in columns or rows indicated BK are in black in the figure. Other colours and other arrangements are also useful. It is to be understood that some embodiments of the invention are suitable for implementation on a Jacquard-type type loom. Some embodiments are suitable for implementation on a dobby-type loom. Other looms with modification if required may also be useful in some embodiments. Embodiments of the present invention are not limited to the fabrication of cushion covers, pillow cases or curtains. For example, garments such as dresses, shirts, T- shirts, blouses, trousers and the like can also be fabricated. Garments may be fabricated with substantially no joining operations required. In some embodiments garments may be fabricated with fewer joining operations than might otherwise be required. A number of other articles may benefit from being fabricated according to embodiments of the present invention including cloth for sails for marine vessels where pockets for battens and the like may be required, tents, awnings, gazebos and a host of other applications. It is to be understood that fabrics used in some embodiments, in particular face fabrics viewed by a user, may for example be of a woven design and piece dyed. The face may for example be polyester, with a cotton lining. The polyester and cotton could be dyed to two different colours in the same dye bath. In the case of a colour woven fabric the threads in the warp and weft could be dyed before weaving and there could therefore be no restriction on the type of fibre used in some embodiments. In the case of a cotton lining, the cotton back or lining might for example first be dyed to a beige or neutral colour, and the face prepared for transfer printing. Substantially any design can then be printed onto the face.

It is to be understood that other arrangements are also useful.

FIG. 9 (a) is a plan view of a length of a fabric 301 according to a further embodiment of the invention suitable for manufacture of a curtain. The fabric 301 is woven in such a manner as to incorporate alternate stripes 322, 324 of a hook yarn and a loop yarn respectively across a width thereof. The positions of the hook stripes 322 and the loop stripes 324 may be reversed in some embodiments. The stripes 322, 324 may be on the same or opposite sides of the fabric 301. In the embodiment shown the stripes 322 of hook yarn are provided at repeat intervals of length L1 as the fabric 301 is woven and the stripes 324 of loop yarn are provided a distance 2(L1 -L2) from the stripes 322 of loop yarn.

It is to be understood that the fabric 301 may be cut at intervals of length L1 after weaving, for example along line A-A in order to form lengths of curtain material 301 C as shown in FIG. 9(b). The material 301 C may then be folded along line B-B and the hook stripes 322 and loop stripes 324 coupled to one another as shown in FIG. 9(b). It is to be understood that this enables a reduction in a hung length of the curtain material 301 C from L1 to L2. The presence of the hook and loop stripes 322, 324 enable a user to conveniently reduce the length of the curtain material 301 C without cutting. A lower edge 301 CL of the material 301 may therefore be made more aesthetically appealing because it is formed by a crease or fold rather than a cut.

It is to be understood that after folding the curtain material 301 C the edge 301 CL may be made more aesthetically pleasing by pressing, for example with a press or iron.

In some embodiments, a yarn comprising a heat activated adhesive may be incorporated into the material 301 C. The yarn may be incorporated such that cut line A-A bisects or otherwise divides the region in which the yarn comprising heat activated adhesive is incorporated. It is to be understood that after cutting along line A-A, one or both free ends of the material 301 C may have a stripe or other portion of heat activated adhesive provided thereat depending on the location of line A-A. Thus one or both free ends may be folded over and the heat activated adhesive activated to form a hem in a convenient manner, for example by pressing with an iron. The material 301 C may be formed such that lower stripe 324 is a sufficient distance from the line A-A along which the fabric 301 is cut to allow the yarn comprising heat activated adhesive to be provided in the region between stripe 324 and line A-A. This allows a lower edge of the length of curtain material 301 C to be hemmed in a convenient manner. It is to be understood that if it is required to shorten the length of curtain material 301 C the material 301 C may be folded along line B-B to form a new lower edge 301 CL.

Alternatively or in addition, in some embodiments two or more repeat units of hook and loop stripes 322, 324 may be incorporated into each piece of material 301 C. FIG. 7 shows an example of a piece of curtain material 401 C having three repeat units of hook stripe 422 and loop stripe 424 woven therein, and a stripe 426 that includes a heat activated yarn. In the embodiment shown in FIG. 10 the respective stripes 422, 424 are substantially adjacent one another, sharing a common boundary. In some alternative embodiments the respective stripes 422, 424 may be spaced apart from one another, or respective repeat units of stripes 422, 424 may be spaced apart. It is to be understood that in some embodiments, upon folding the material 401 C more than one respective hook stripe 422 and more than one respective loop stripe 424 may be coupled together depending on where the material 401 C is folded. In some embodiments a hem may be formed by folding the material and coupling respective hook and loop stripes 422, 424 at a plurality of locations without a requirement to incorporate into the material 401 C the stripe 426 that includes the yarn comprising heat activated adhesive. In some embodiments including that of FIG. 10 the stripe 426 is provided at or close to a free edge of the material 401 C. Other arrangements are also useful.

It is to be understood that embodiments of the present invention enable incorporation of hook yarn or loop yarn into a fabric as the article is being woven. Thus hook and loop fastenings of the Velcro (RTM) type may be incorporated into an article directly without a requirement for post-weaving stitching or gluing of hook and loop tape into the article. A substantial reduction in finishing costs associated with an article may therefore be enjoyed.

FIG. 10 shows a fabric 501 in which a T-shirt garment 510 has been woven. The fabric 501 is formed from a single layer of material, except in the shaded region 510 where the fabric is double layered.

The fabric 501 may be cut through the single layer around and close to the border of the garment, e.g. along the dotted line shown in FIG. 1 1 after weaving in order to separate the garment 510 from the remainder of the fabric 501 . Free edges 510 may be formed in the garment 510 to allow the garment 510 to be turned inside out and worn by the user. In some arrangements the edges 510 may be formed by cutting. Hems may then be formed if required. In embodiments where yarn comprising heat- activate adhesive has been provided in the garment 510 hems may be formed by folding the fabric and applying heat and pressure. Other arrangements are also useful.

It its to be understood that more complex garments may be fabricated by extension, optionally with one or more further inner and/or outer layers.

Attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.

All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.

Each feature disclosed in this specification (including any accompanying claims, abstract and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features. The invention is not restricted to the details of the foregoing embodiment(s). The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.