Login| Sign Up| Help| Contact|

Patent Searching and Data


Title:
TEXTILE AND METHOD OF PRODUCING A TEXTILE
Document Type and Number:
WIPO Patent Application WO/2023/002217
Kind Code:
A1
Abstract:
A method of producing a textile, the method comprising the steps of weaving a first yarn to produce a first part of a textile, weaving a second yarn to produce a second part of the textile, weaving at least a portion of the first part of the textile to at least a portion of the second part of the textile by weaving a sacrificial yarn to the first part of the textile and the second part of the textile, and removing at least a portion of the sacrificial yarn from the textile.

Inventors:
DEWAR AILIS MARGARET (GB)
PERKINS EMILY KATHERINE (GB)
ROGERS IAN DAVID (GB)
Application Number:
PCT/GB2022/051932
Publication Date:
January 26, 2023
Filing Date:
July 22, 2022
Export Citation:
Click for automatic bibliography generation   Help
Assignee:
MOORBROOK TEXTILES LTD (GB)
International Classes:
D03D11/02; D03D15/54; D03D15/68
Foreign References:
US20090288731A12009-11-26
EP2325357A22011-05-25
US20140166548A12014-06-19
US2435543A1948-02-03
Attorney, Agent or Firm:
LAWRIE IP LIMITED (GB)
Download PDF:
Claims:
Claims

1. A method of producing a textile, the method comprising the steps of: weaving a first yarn to produce a first part of a textile; weaving a second yarn to produce a second part of the textile; weaving at least a portion of the first part of the textile to at least a portion of the second part of the textile by weaving a sacrificial yarn to the first part of the textile and the second part of the textile; and removing at least a portion of the sacrificial yarn from the textile.

2. The method of claim 1 , wherein the first part of the textile is a sheet or layer of the textile and wherein the second part of the textile is a sheet or layer of the textile.

3. The method of claim 1 or claim 2, wherein at least a portion of the first part of the textile is arranged to overlay at least a portion of the second part of the textile.

4. The method of any preceding claim, wherein the step of weaving the sacrificial yarn includes weaving a plurality of sacrificial yarns to the first part of the textile and to the second part of the textile.

5. The method of any preceding claim, wherein the sacrificial yarn has at least one different material property than the first yarn and/or the second yarn.

6. The method of any preceding claim, wherein the first yarn is provided from one or more sources of first yarn, the second yarn is provided from one or more sources of second yarn, wherein the sacrificial yarn is provided from one or more, or a plurality of sources of sacrificial yarn, and wherein the, or each, source of sacrificial yarn is different to the one or more sources of first yarn and/or the one or more sources of second yarn.

7. The method of any preceding claim, wherein the method comprises the step of placing the sacrificial yarn under tension, wherein the step of placing the sacrificial yarn under tension is carried out prior to the step of weaving the sacrificial yarn to the first part and the second part of the textile.

8. The method of claim 7, wherein the method comprises the step of placing the first yarn and/or the second yarn under tension, and the method comprises the step of independently tensioning the sacrificial yarn and the first yarn and/or the second yarn.

9. The method of any preceding claim, wherein the sacrificial yarn comprises one or more polymer materials. 10. The method of any preceding claim, wherein the sacrificial yarn is a non-fibrous yarn.

11. The method of any preceding claim, wherein the method comprises the step of arranging the sacrificial yarn in a warp direction and/or a weft direction prior to, or during, the step of weaving the sacrificial yarn.

12. The method of claim 11 , wherein the method comprises the step of arranging a plurality of strands of the sacrificial yarn in the warp direction and/or in the weft direction. 13. The method of any preceding claim, wherein the sacrificial yarn is woven to the first part of the textile and/or the second part of the textile at a ratio of warp to weft of at least 1:1, optionally at least 2:1 , optionally at least 3: 1 , optionally at least 4: 1 , optionally at least 5: 1 , optionally at least 6:1, optionally at least 8:1, optionally at least 12:1, optionally at least 20:1, optionally at least 50: 1 , optionally at least 70: 1 , optionally at least 75: 1 , optionally at least 100:1, optionally at least 120:1, optionally at least 150:1, optionally at least 180: 1 , optionally at least 200: 1 , optionally at least 250: 1 , optionally at least 280:1, optionally at least 300:1, optionally between 70:1 and 350:1, optionally between 75:1 and 300:1, optionally between 70:1 and 125:1, optionally between 75:1 and 120:1, optionally between 190:1 and 310:1, optionally between 200: 1 and 300: 1.

14. The method of any preceding claim, wherein at least a part of the step of weaving the first yarn to produce the first part of the textile is carried out substantially simultaneously to at least a part of the step of weaving the second yarn to produce the second part of the textile.

15. The method of any preceding claim, wherein at least a part of the step of weaving the first yarn to produce the first part of the textile is carried out substantially simultaneously to the step of weaving the sacrificial yarn to the first part of the textile and the second part of the textile. 16. The method of any preceding claim, wherein at least a part of the step of weaving the second yarn to produce the second part of the textile is carried out substantially simultaneously to the step of weaving the sacrificial yarn to the first part of the textile and the second part of the textile. 17. The method of any preceding claim, wherein the step of weaving at least a portion of the first part of the of the textile to at least a portion of the second part of the textile comprises the step of weaving the first yarn directly to the second yarn and/or weaving a further yarn to the first part and the second part of the textile.

18. The method of claim 17, wherein at least a part of the step of weaving the first yarn to the second yarn is carried out substantially simultaneously to the step of weaving the sacrificial yarn to the first part and the second part of the textile.

19. The method of any preceding claim, wherein the step of removing at least a portion of the sacrificial yarn is carried out after the step of weaving the first part of the textile, after the step of weaving the second part of the textile and after the step of weaving the sacrificial yarn to the first part and the second part of the textile.

20. The method of any preceding claim, wherein the method comprises the step of removing substantially all of the sacrificial yarn from the textile.

21. The method of any preceding claim, wherein the step of removing at least a portion of the sacrificial yarn from the textile is carried out using a manual process. 22. The method of any preceding claim, wherein the step of removing at least a portion of the sacrificial yarn from the textile creates, or enlarges, one or more openings, gaps, or pockets of space between the first part of the textile and the second part of the textile. 23. The method of claim 22, wherein the step of removing at least a portion of the sacrificial yarn from the textile creates an opening between the first part and the second part of the textile running from at least one side, or edge, of the textile to another side, or edge of the textile.

24. The method of any of claims 21 to 23, wherein the step of removing at least a portion of the sacrificial yarn is carried out by hand or by using a hand tool. 25. The method of any of claims 21 to 24, wherein the step of removing at least a portion of the sacrificial yarn from the textile is carried out by pulling one or more strands of the sacrificial yarn from the textile.

26. The method of any of claims 21 to 25, wherein the step of removing at least a portion of the sacrificial yarn from the textile is carried out by extracting one or more strands of the sacrificial yarn from the textile.

27. The method of claim 26, wherein the step of removing at least a portion of the sacrificial yarn from the textile is carried out by manually extracting one or more strands of the sacrificial yarn from the textile.

28. The method of any preceding claim, wherein the step of removing at least a portion of the sacrificial yarn is a non-destructive removal step. 29. The method of claim 28, wherein the step of removing at least a portion of the sacrificial yarn is configured to be non-destructive to substantially all of the first yarn and/or the second yarn. 30. The method of claim 28 or claim 29, wherein the step of removing the sacrificial yarn is configured to be non-destructive to at least a portion of the sacrificial yarn, or to substantially all of the sacrificial yarn. 31. The method of any of claims 20 to 30, wherein the step of removing at least a portion of the sacrificial yarn includes removing the sacrificial yarn substantially intact.

32. The method of any preceding claim, wherein the sacrificial yarn is biodegradable, or includes one or more biodegradable materials.

33. The method of any of claims 1 to 8, wherein the sacrificial yarn is a non-plastic yarn or is formed from one or more non-plastic materials. 34. The method of any preceding claim, wherein the sacrificial yarn is formed from one or more naturally occurring materials.

35. A method of producing a garment, the method comprising the steps of: weaving a first yarn to produce a first part of a garment; weaving a second yarn to produce a second part of the garment; weaving at least a portion of the first part of the garment to at least a portion of the second part of the garment by weaving a sacrificial yarn to the first part of the garment and the second part of the garment; and removing at least a portion of the sacrificial yarn from the garment.

36. A textile produced using the method of any of claims 1 to 34.

37. A garment, wherein at least a portion of the garment is produced using the method of claim 35.

Description:
Textile and Method of Producing a Textile

Field of the invention The present invention relates to a method of producing a textile and particularly, but not exclusively, to a method of weaving using a sacrificial yarn.

Background to the invention

Weaving two layers or sheets of a garment together can be carried out by weaving yarns from one sheet to the other sheet. This limits the design of the garment. For example, if the layers are made from different coloured yarns, the process of weaving them together may mean that colour from the second sheet is visible on the first sheet and vice versa.

For some garments, such as scarfs, it may be desirable to include an opening, or gap, between two or more layers of fabric. Flowever, such an opening may make the scarf more difficult to process using conventional weaving and processing techniques, as the two sheets can move relative to each other, which may reduce the quality of the finished garment.

The inventors have appreciated the shortcomings in known textile production processes. Statements of Invention

According to a first aspect of the present invention there is provided a method of producing a textile, the method comprising the steps of: weaving a first yarn to produce a first part of a textile; weaving a second yarn to produce a second part of the textile; and weaving at least a portion of the first part of the textile to at least a portion of the second part of the textile by weaving a sacrificial yarn to the first part of the textile and the second part of the textile; and removing at least a portion of the sacrificial yarn from the textile.

The first part of the textile may be a sheet or layer of the textile. The second part of the textile may be a sheet or layer of the textile. The first part of the textile may be substantially planar, or substantially flat. The second part of the textile may be substantially planar or substantially flat.

The first part of the textile and the second part of the textile may be arranged to form a double layer textile.

The first part of the textile may form an outer layer of the textile. The second part of the textile may form an outer layer of the textile. The first part of the textile may form an outer layer of the textile and the second part of the textile may form an outer layer of the textile.

The first part of the textile and the second part of the textile may be arranged opposite each other. The first part and the second part of the textile may be opposing layers of the textile.

At least a portion of the first part may be arranged to overlay at least a portion of the second part. The first part of the textile may be arranged to substantially overlay the second part of the textile. Substantially all of the first part of the textile may be arranged to substantially overlay the second part of the textile. Two or more first yarns may be used to weave the first part of the textile. Two or more second yarns may be used to weave the first part of the textile. The first yarn may be the same as the second yarn. The first yarn may be different to the second yarn. The sacrificial yarn may comprise one or more yarns, or a plurality of yarns. Two or more sacrificial yarns may be used in the step of weaving the sacrificial yarn to the first part and the second part of the textile.

The first yarn may be provided from one or more sources of first yarn. The second yarn may be provided from one or more sources of second yarn. The sacrificial yarn may be provided from one or more sources of sacrificial yarn.

The step of weaving the sacrificial yarn may include weaving a plurality of sacrificial yarns to the first part of the textile and to the second part of the textile. The step of weaving the sacrificial yarn may include weaving a plurality of strands of the sacrificial yarn to the first part of the textile and to the second part of the textile. The plurality of sacrificial yarns may be provided from one or more, or a plurality of sources of sacrificial yarn.

The, or each, source of sacrificial yarn may be different to the one or more sources of first yarn and/or the one or more sources of second yarn.

The first yarn may be provided from one or more sources of first yarn, the second yarn may be provided from one or more sources of second yarn, the sacrificial yarn may be provided from one or more, or a plurality of sources of sacrificial yarn, and the, or each, source of sacrificial yarn may be different to the one or more sources of first yarn and/or the one or more sources of second yarn.

The step of weaving the sacrificial yarn may include weaving three or more sacrificial yarns to the first part of the textile and to the second part of the textile, optionally four or more sacrificial yarns, optionally five or more sacrificial yarns, optionally six or more sacrificial yarns, optionally eight or more sacrificial yarns, optionally ten or more sacrificial yarns.

Each sacrificial yarn may be provided from one or more sources of sacrificial yarn. Each sacrificial yarn may be provided by an independent source of sacrificial yarn. The two or more sacrificial yarns may be spaced apart in the horizontal direction by at least 2cm, optionally by at least 4 cm, optionally by at least 6cm, optionally by at least 7cm, optionally by between 2cm and 14cm, optionally by between 4cm and 12cm, optionally by between 6cm and 10cm, optionally 7cm.

The step of weaving the sacrificial yarn to the first part and the second part of the textile may include at least 10 weft picks of the sacrificial yarn to the first part and at least 10 weft picks of the sacrificial yarn to the second part, optionally at least 20 weft picks to the first and second parts, optionally at least 30 weft picks to the first and second parts, optionally at least 40 weft picks, optionally at least 50 weft picks, optionally at least 60 weft picks, optionally at least 70 weft picks, optionally at least 75 weft picks, optionally at least 100 weft picks, optionally at least 120 weft picks, optionally at least 150 weft picks, optionally at least 180 weft picks, optionally at least 200 weft picks, optionally at least 250 weft picks, optionally at least 280 weft picks, optionally at least 300 weft picks, optionally between 70 weft picks and 350 weft picks, optionally between 75 weft picks and 300 weft picks, optionally between 70 weft picks and 125 weft picks, optionally between 75 weft picks and 120 weft picks, optionally between 190 weft picks and 310 weft picks, optionally between 200 weft picks and 300 weft picks.

The method may comprise the step of placing the sacrificial yarn under tension. The method may comprise the step of placing the warp sacrificial yarn, or yarns, under tension. The step of placing the sacrificial yarn under tension may be carried out prior to the step of weaving the sacrificial yarn to the first part and the second part of the textile. The method may comprise the step of placing the sacrificial yarn under tension, and the step of placing the sacrificial yarn under tension may be carried out prior to the step of weaving the sacrificial yarn to the first part and the second part of the textile.

The method may comprise the step of placing the first yarn and/or the second yarn under tension. The method may comprise the step of independently tensioning the sacrificial yarn and the first yarn and/or the second yarn. The method may comprise the step of placing the first yarn and/or the second yarn under tension, and the method may comprise the step of independently tensioning the sacrificial yarn and the first yarn and/or the second yarn.

The sacrificial yarn may be formed of a material that is different to the first yarn and/or the second yarn. The sacrificial yarn may include at least one different material to the first yarn and/or the second yarn. The sacrificial yarn may be a substantially different yarn to the first yarn and/or the second yarn.

The sacrificial yarn may be substantially the same yarn as the first yarn and/or the second yarn.

The sacrificial yarn may comprise one or more polymer materials. The polymer material may be polyester. The polymer material may be a white polyester, a natural white polyester, or the like.

The sacrificial yarn may be water-insoluble. The sacrificial yarn may be water-soluble. The sacrificial yarn may include a water-insoluble material or a water-soluble material. The sacrificial yarn may comprise a water- insoluble polymer. The sacrificial yarn may comprise a water-soluble polymer.

The sacrificial yarn may have at least one different material property than the first yarn and/or the second yarn. The sacrificial yarn may have a different appearance to the first yarn and/or the second yarn. At least a portion of the sacrificial yarn may have a different colour to at least a portion of the first yarn and/or the second yarn.

The sacrificial yarn may be a non-fibrous yarn. The first yarn and/or the second yarn may be a fibrous yarn. The sacrificial yarn may be a non- fibrous yarn and the first yarn and/or the second yarn may be a fibrous yarn.

The sacrificial yarn may comprise one or more filaments. The sacrificial yarn may be a mono-filament yarn. The coefficient of friction of the sacrificial yarn on the first yarn may be lower than the coefficient of friction of the first yarn to the second yarn.

The coefficient of friction of the sacrificial yarn on the second yarn may be lower than the coefficient of friction of the first yarn to the second yarn.

The sacrificial yarn may be biodegradable. The sacrificial yarn may include one or more biodegradable materials.

The sacrificial yarn may be a non-plastic yarn. The sacrificial yarn may be formed from one or more non-plastic materials. The sacrificial yarn may be formed from one or more naturally occurring materials.

The sacrificial yarn may have a strength of between 500 cN and 2,500 cN, optionally between 600 cN and 2,200 cN, optionally between 700 cN and 1,100 cN, optionally between 850 cN and 1,000 cN, optionally between

900 cN and 940 cN, optionally approximately 920 cN.

The sacrificial yarn may be configured to have an elongation range of between 15 % to 23 %, optionally between 16 % to 22 %.

The sacrificial yarn may have a Tex value of between 8 and 40, optionally between 10 and 20, optionally between 10 and 15, optionally 12.

The method may comprise the step of arranging the first yarn in a warp direction. The method may comprise the step of arranging the first yarn in a weft direction. The method may comprise the step of arranging one or more first yarns in a warp direction and one or more first yarns in a weft direction. The method may comprise the step of arranging the second yarn in a warp direction. The method may comprise the step of arranging the second yarn in a weft direction. The method may comprise the step of arranging one or more second yarns in a warp direction and one or more second yarns in a weft direction.

The step of arranging the first yarn in the warp direction or the weft direction may be carried out prior to the step of weaving the first part of the textile. The step of arranging the first yarn in the warp direction may be carried out during the step of weaving the first part of the textile.

The step of arranging the second yarn in the warp direction or the weft direction may be carried out prior to the step of weaving the second part of the textile. The step of arranging the second yarn in the warp direction may be carried out during the step of weaving the second part of the textile.

The method may comprise the step of arranging the sacrificial yarn in a warp direction. The method may comprise the step of arranging the sacrificial yarn in a weft direction. The method may comprise the step of arranging the sacrificial yarn in a warp direction and/or a weft direction.

The method may comprise the step of arranging one or more sacrificial yarns in a warp direction. The method may comprise the step of arranging one or more sacrificial yarns in a weft direction.

The step of arranging the sacrificial yarn in the warp direction may be carried out prior to the step of weaving the sacrificial yarn.

The step of arranging the sacrificial yarn in the weft direction may be carried out prior to, or during, the step of weaving the sacrificial yarn. The step of arranging the sacrificial yarn in the warp direction and/or the weft direction may be carried out prior to, or during, the step of weaving the sacrificial yarn.

The sacrificial yarn may be woven to the first part and the second part of the textile by weaving one or more sacrificial yarn warps to one or more first yarn wefts and one or more second yarn wefts. The sacrificial yarn may be woven to the first part and the second part of the textile by weaving one or more first yarn warps and one or more second yarn warps to one or more sacrificial yarn wefts. The sacrificial yarn may be woven to the first part and the second part of the textile by weaving one or more sacrificial yarn warps to one or more first yarn wefts and one or more second yarn wefts and/or weaving one or more first yarn warps and one or more second yarn warps to one or more sacrificial wefts. The sacrificial yarn may be woven to the first part and the second part of the textile using any suitable warp and weft arrangement of the first yarn, the second yarn, and the sacrificial yarn. The method may comprise the step of arranging one or more strands of the sacrificial yarn in the warp direction and/or in the weft direction. The method may comprise the step of arranging a plurality of strands of the sacrificial yarn in the warp direction and/or in the weft direction. The method may comprise the step of arranging the, or each, strand of sacrificial yarn between two or more strands of the first yarn. The method may comprise the step of arranging the sacrificial yarn between two or more strands of the second yarn. The sacrificial yarn may be woven to the first part and the second part of the textile by arranging the sacrificial yarn only in the warp direction, or only in the weft direction. The method may comprise the step of arranging the sacrificial yarn independently of the first yarn and/or of the second yarn. The sacrificial yarn may be arranged independently in the warp direction and/or the weft direction. The sacrificial yarn may be a separate yarn from the first yarn and/or the second yarn.

The sacrificial yarn may be woven to the first part of the textile and/or the second part of the textile at a ratio of warp to weft of at least 1:1, optionally at least 2:1, optionally at least 3: 1 , optionally at least 4: 1 , optionally at least 5: 1 , optionally at least 6: 1 , optionally at least 8: 1 , optionally at least 12:1, optionally at least 20: 1 , optionally at least 50: 1 , optionally at least 70:1 , optionally at least 75:1 , optionally at least 100:1 , optionally at least 120: 1 , optionally at least 150: 1 , optionally at least 180: 1 , optionally at least 200:1 , optionally at least 250:1 , optionally at least 280:1 , optionally at least

300:1, optionally between 70:1 and 350:1, optionally between 75:1 and 300:1, optionally between 70:1 and 125:1, optionally between 75:1 and 120:1, optionally between 190:1 and 310:1, optionally between 200:1 and 300:1.

The weave between the sacrificial yarn and the first part and the second part of the textile may comprise warp sacrificial yarn and weft first yarn or weft second yarn. The sacrificial yarn may be woven to the first part of the textile and/or the second part of the textile at a ratio of warp to weft of at least 1:1, optionally at least 2: 1 , optionally at least 3: 1 , optionally at least 4:1 , optionally at least 5:1 , optionally at least 6:1 , optionally at least 8:1 , optionally at least 12:1, optionally at least 20: 1 , , optionally at least 50: 1 , optionally at least 70:1 , optionally at least 75:1 , optionally at least 100:1 , optionally at least 120:1, optionally at least 150:1, optionally at least 180:1, optionally at least 200: 1 , optionally at least 250: 1 , optionally at least 280: 1 , optionally at least 300:1, optionally between 70:1 and 350:1, optionally between 75:1 and 300:1, optionally between 70:1 and 125:1, optionally between 75:1 and 120:1, optionally between 190:1 and 310:1, optionally between 200:1 and 300:1 , referring to the sacrificial yarn in the warp direction and the first yarn or second yarn in the weft direction.

The weave between the sacrificial yarn and the first part and the second part of the textile may comprise weft sacrificial yarn and warp first yarn or warp second yarn. The sacrificial yarn may be woven to the first part of the textile and/or the second part of the textile at a ratio of warp to weft of at least 1:1, optionally at least 2:1 , optionally at least 3:1 , optionally at least 4: 1 , optionally at least 5: 1 , optionally at least 6: 1 , optionally at least 8: 1 , optionally at least 12:1, optionally at least 20: 1 , , optionally at least 50: 1 , optionally at least 70: 1 , optionally at least 75: 1 , optionally at least 100: 1 , optionally at least 120: 1 , optionally at least 150: 1 , optionally at least

180: 1 , optionally at least 200: 1 , optionally at least 250: 1 , optionally at least 280:1, optionally at least 300:1, optionally between 70:1 and 350:1, optionally between 75:1 and 300:1, optionally between 70:1 and 125:1, optionally between 75:1 and 120:1, optionally between 190:1 and 310:1, optionally between 200:1 and 300:1 , referring to the sacrificial yarn in the weft direction and the first yarn or second yarn in the warp direction.

The step of weaving the sacrificial yarn to the first and second parts of the textile may include weaving the sacrificial yarn to at least one of: a mid region, a central region, one or more end regions, one or more vertical end regions, one or more horizontal end regions, one or more upper regions, one or more mid-upper regions, one or more mid-lower regions, one or more lower regions, one or more side regions, one or more right side regions, one or more left side regions, one or more mid-side regions, one or more mid-right side regions, one or more mid-left side regions, and one or more border or perimeter regions, of the first part and/or the second part of the textile.

The step of weaving the sacrificial yarn to the first and second parts of the textile may comprise weaving the sacrificial yarn at one or more, or two or more, or three or more, or four or more regions of the first part and the second part of the textile. The step of weaving the sacrificial yarn to the first and second parts of the textile may comprise weaving the sacrificial yarn at one or more, or two or more, or three or more, or four or more warp yarns and/or one or more, two or more, three or more, or four or more weft yarns of the first part and the second part of the textile.

The method may comprise the step of providing one or more guide members for the sacrificial yarn. The guide member may be a heddle, or the like. The guide member may be operable to move the sacrificial warp yarn, or yarns, during weaving.

The method may comprise the step of providing one or more guide members for the first yarn. The guide member may be a heddle, or the like. The guide member may be operable to move the first warp yarn, or yarns, during weaving.

The method may comprise the step of providing one or more guide members for the second yarn. The guide member may be a heddle, or the like. The guide member may be operable to move the second warp yarn, or yarns, during weaving.

The method may comprise at least one step of guiding, or moving, the sacrificial yarn independently of the first yarn and/or the second yarn during the step of weaving the sacrificial yarn. The guiding or moving of the sacrificial yarn may be carried out in accordance with any suitable weaving technique. The step of weaving the sacrificial yarn to the first and second parts of the textile may comprise a plurality of steps of weaving the sacrificial yarn to the first and second parts of the textile.

At least a part of the step of weaving the first yarn to produce the first part of the textile may be carried out substantially simultaneously to at least a part of the step of weaving the second yarn to produce the second part of the textile. At least a part of the step of weaving the first yarn to produce the first part of the textile may be carried out during the step of weaving the second yarn to produce the second part of the textile.

At least a part of the step of weaving the first yarn to produce the first part of the textile may be carried out substantially simultaneously to the step of weaving the sacrificial yarn to the first part of the textile and the second part of the textile. At least a part of the step of weaving the first yarn to produce the first part of the textile may be carried out during the step of weaving the sacrificial yarn to the first part of the textile and the second part of the textile.

At least a part of the step of weaving the second yarn to produce the second part of the textile may be carried out substantially simultaneously to the step of weaving the sacrificial yarn to the first part of the textile and the second part of the textile. At least a part of the step of weaving the second yarn to produce the second part of the textile may be carried out during the step of weaving the sacrificial yarn to the first part of the textile and the second part of the textile.

At least a part of the steps of weaving the first part, the second part, and the sacrificial yarn to the first part and the second part may be carried out substantially simultaneously. The steps of weaving the first part, the second part, and the sacrificial yarn to the first part and the second part may be carried out substantially simultaneously.

The step of weaving at least a portion of the first part of the of the textile to at least a portion of the second part of the textile may comprise the step of weaving the first yarn to the second yarn. At least a part of the step of weaving the first yarn to the second yarn may be carried out substantially simultaneously to the step of weaving the sacrificial yarn to the first part and the second part of the textile. At least a part of the step of weaving the first yarn to the second yarn may be carried out during the step of weaving the sacrificial yarn to the first part and the second part of the textile.

The step of weaving the first yarn to the second yarn may comprise the step of weaving the first yarn directly to the second yarn and/or weaving a further yarn to the first part and the second part of the textile. The further yarn may be different to the sacrificial yarn.

The step of weaving at least a portion of the first part of the of the textile to at least a portion of the second part of the textile may include weaving the first yarn to the second yarn at at least one of: a mid region, one or more end regions, one or more vertical end regions, one or more horizontal end regions, one or more upper regions, one or more mid-upper regions, one or more mid-lower regions, one or more lower regions, one or more side regions, one or more right side regions, one or more left side regions, one or more mid-side regions, one or more mid-right side regions, one or more mid-left side regions, and one or more border or perimeter regions, of the first part and/or the second part of the textile.

The step of weaving at least a portion of the first part of the of the textile to at least a portion of the second part of the textile may include weaving the first yarn to the second yarn at one or more, or two or more, or three or more, or four or more regions of the first part and the second part of the textile. The method may comprise the step of removing substantially all of the sacrificial yarn from the textile.

The step of removing substantially all of the sacrificial yarn from the textile may detach the first part of the textile from the second part of the textile. In this example, the method produces a plurality of textiles, as the first part and the second part form separate textiles after the removal of the sacrificial yarn.

The step of removing at least a portion of the sacrificial yarn may be carried out separately to the weaving steps of the method. The step of removing at least a portion of the sacrificial yarn may be carried out after the step of weaving the first part of the textile. The step of removing at least a portion of the sacrificial yarn may be carried out after the step of weaving the second part of the textile. The step of removing at least a portion of the sacrificial yarn may be carried out after the step of weaving the sacrificial yarn to the first part and the second part of the textile. The step of removing at least a portion of the sacrificial yarn may be carried out after the step of weaving the first part of the textile, after the step of weaving the second part of the textile and after the step of weaving the sacrificial yarn to the first part and the second part of the textile.

The step of removing at least a portion of the sacrificial yarn may be carried out after the step of weaving the first yarn directly to the second yarn and/or weaving a further yarn to the first part and the second part of the textile.

The step of removing at least a portion of the sacrificial yarn from the textile may be carried out using a manual process. The step of removing at least a portion of the sacrificial yarn from the textile may be carried out by hand. The step of removing at least a portion of the sacrificial yarn from the textile may be carried out by hand or by using a hand tool.

The step of removing substantially all of the sacrificial yarn from the textile may be carried out using a manual process. The step of removing substantially all of the sacrificial yarn from the textile may be carried out by hand. The step of removing substantially all of the sacrificial yarn from the textile may be carried out by hand or by using a hand-operated tool.

The step of removing at least a portion of the sacrificial yarn from the textile may be carried out by pulling one or more strands of the sacrificial yarn from the textile. The step of removing at least a portion of the sacrificial yarn from the textile may be carried out by extracting one or more strands of the sacrificial yarn from the textile. The step of removing at least a portion of the sacrificial yarn from the textile may be carried out by manually extracting one or more strands of the sacrificial yarn from the textile.

The step of removing substantially all of the sacrificial yarn from the textile may be carried out by pulling one or more strands of the sacrificial yarn from the textile. The step of removing substantially all of the sacrificial yarn from the textile may be carried out by extracting one or more strands of the sacrificial yarn from the textile. The step of removing substantially all of the sacrificial yarn from the textile may be carried out by manually extracting the, or each strand of the sacrificial yarn from the textile.

The method may comprise a plurality of sacrificial yarn removal steps, each removal step removing at least a portion of the sacrificial yarn from the textile.

The step of removing at least a portion of the sacrificial yarn may include removing the sacrificial yarn substantially intact. The sacrificial yarn, once removed from the textile, may be re-usable in a further method of producing a textile. The sacrificial yarn may be substantially unmodified after removal from the textile. The step of removing substantially all of the sacrificial yarn may include removing the sacrificial yarn substantially intact.

The removal step may be a non-destructive removal step. The step of removing at least a portion of the sacrificial yarn may be configured to be non-destructive to substantially all of the first yarn and/or the second yarn. The step of removing the sacrificial yarn may be configured to be non destructive to at least a portion of the sacrificial yarn, or to substantially all of the sacrificial yarn. The, or each, step of removing at least a portion of the sacrificial yarn from the textile may create, or enlarge, one or more openings, gaps, or pockets of space between the first part of the textile and the second part of the textile.

The, or each, step of removing at least a portion of the sacrificial yarn from the textile may detach at least a portion of the first part of the textile from at least a portion of the second part of the textile. The, or each, step of removing at least a portion of the sacrificial yarn from the textile may detach a plurality of portions of the first part of the textile from at least a portion of the second part of the textile.

At least one step of removing at least a portion of the sacrificial yarn from the textile may create an opening between the first part and the second part of the textile running from at least one side, or edge, of the textile to another side, or edge of the textile. The opening may run from a vertical edge, or side, to another vertical edge, or side. The opening may run from a horizontal side, or edge, to another horizontal edge, or side. The opening may run from a vertical edge, or side, to another vertical edge, or side and/or the opening may run from a horizontal side, or edge, to another horizontal edge, or side.

The method may comprise one or more textile processing steps. One or more textile processing steps may be carried out between the step of weaving the sacrificial yarn and the step of removing at least a portion of the sacrificial yarn from the textile. The textile processing steps may include one or more weaving steps, or weaving finishing steps.

The textile may be a fabric. The textile may be for producing a garment. The textile may be at least a portion of a garment. The garment may be a scarf, a pocket scarf, pocket cloth scarf, or the like.

The first part of the textile may be woven using one or more weave patterns. The one or more weave patterns may be a plain weave.

The second part of the textile may be woven using one or more weave patterns. The one or more weave patterns may be a plain weave. The step of weaving the sacrificial yarn to the first part and the second part of the textile may be carried out using one or more weave patterns. The weave pattern may be an offset weave pattern.

The method may comprise the step of providing a weaving apparatus. The weaving apparatus may be operable to carry out any one or all of the steps of the method. The weaving apparatus may be operable to automatically carry out any one or all of the steps of the method. The weaving apparatus may be operable to automatically carry out any one or all of the steps of the method in response to one or more user-input signals being provided to the weaving apparatus.

The weaving apparatus may be a mechanised weaving apparatus. The weaving apparatus may comprise one or more automated looms. The weaving apparatus may comprise one or more motors operable to automatically carry out one or more of the weaving steps of the method.

Any one or all of the weaving steps may be carried out using a dobby weave, or a jacquard weave, or any suitable weave. Unless otherwise stated, the steps of the method may be carried out in any order and may be interchanged as required in order to implement the method of the invention. According to a second aspect of the present invention there is provided a method of producing a garment, the method comprising the steps of: weaving a first yarn to produce a first part of a garment; weaving a second yarn to produce a second part of the garment; weaving at least a portion of the first part of the garment to at least a portion of the second part of the garment by weaving a sacrificial yarn to the first part of the garment and the second part of the garment; and removing at least a portion of the sacrificial yarn from the garment.

Embodiments of the second aspect of the present invention may include one or more features of the first aspect of the present invention or its embodiments. Similarly, embodiments of the first aspect of the present invention may include one or more features of the second aspect of the present invention or its embodiments. According to a third aspect of the present invention there is provided a textile produced using the method of the first aspect of the invention.

Embodiments of the third aspect of the present invention may include one or more features of the first and/or second aspects of the present invention or their embodiments. Similarly, embodiments of the first and/or second aspects of the present invention may include one or more features of the third aspect of the present invention or its embodiments. According to a fourth aspect of the present invention there is provided a garment, wherein at least a portion of the garment is produced using the method of the second aspect of the invention. Embodiments of the fourth aspect of the present invention may include one or more features of the first, second and/or third aspects of the present invention or their embodiments. Similarly, embodiments of the first, second, and/or third aspects of the present invention may include one or more features of the fourth aspect of the present invention or its embodiments.

According to a fifth aspect of the present invention there is provided a textile comprising: a first part woven from a first yarn; a second part woven from a second yarn; and a sacrificial yarn woven to the first part and the second part of the textile.

The textile may be a fabric. The textile may be for producing a garment.

The textile may be at least a portion of a garment. The garment may be a scarf, a pocket scarf, pocket cloth scarf, or the like.

Embodiments of the fifth aspect of the present invention may include one or more features of the first, second, third and/or fourth aspects of the present invention or their embodiments. Similarly, embodiments of the first, second, third, and/or fourth aspects of the present invention may include one or more features of the fifth aspect of the present invention or its embodiments. According to a sixth aspect of the present invention there is provided a method of producing a textile, the method comprising the steps of: weaving a first yarn to produce a first part of a textile; weaving a second yarn to produce a second part of the textile; and weaving at least a portion of the first part of the textile to at least a portion of the second part of the textile by weaving a sacrificial yarn to the first part of the textile and the second part of the textile.

Embodiments of the sixth aspect of the present invention may include one or more features of the first, second, third, fourth and/or fifth aspects of the present invention or their embodiments. Similarly, embodiments of the first, second, third, fourth, and/or fifth aspects of the present invention may include one or more features of the sixth aspect of the present invention or its embodiments.

Brief description of the drawings

Embodiments of the invention will now be described, by way of example, with reference to the drawings, in which: Fig. 1 shows a textile being produced in accordance with an embodiment of the invention;

Fig. 2 shows another view of the textile of Fig. 1 , specifically the warp yarns thereof during production;

Fig. 3 shows a closer view of the textile of Fig. 1 ; Fig. 4 shows a textile produced in accordance with an embodiment of the invention;

Fig. 5 shows a magnified view of the textile of Fig. 4;

Fig. 6 shows an alternative embodiment of the invention, in which a sacrificial yarn is arranged in the weft direction; Fig. 7 shows a magnified view of the textile produced using the alternative embodiment of Fig. 6;

Fig. 8 shows sources of sacrificial yarn being used in an embodiment of the invention; Fig. 9 shows another textile produced in accordance with an embodiment of the invention;

Fig. 10 shows a front view of another textile produced in accordance with an embodiment of the invention, in which the two parts of the textile are joined at a mid region; and Fig. 11 shows a rear view of the textile of Fig. 10.

Description of preferred embodiments

A method of producing a textile 1 will now be described with reference to Figs. 1 to 11. In the embodiments illustrated and described here, the textile 1 is fabric for a scarf 2. It will be understood that other types of textiles, fabrics, and garments can be produced using the method of the present invention. For example, the textile 1 could be at least a portion of a garment. The scarf 2 could be any type of scarf, including a pocket scarf, pocket cloth scarf, or the like.

The method comprises the steps of:

(i) weaving a first yarn 4 to produce a first part 6 of the textile 1 ;

(ii) weaving a second yarn 8 to produce a second part 10 of the textile 1 ; and

(iii) weaving at least a portion of the first part 6 of the textile 1 to at least a portion of the second part 10 of the textile 1 by weaving a sacrificial yarn 12 to the first part 6 of the textile 1 and the second part 10 of the textile 1 ; and (iv) removing substantially all of the sacrificial yarn 12 from the textile 1.

Steps (i) to (iii) are carried out substantially simultaneously, and step (iv) is carried out after the weaving steps of (i) to (iii) are carried out. Typically, step (iv) is carried as the final step, once textile processing steps are carried out. It will be appreciated that the steps of the method may be carried out in a different order. Furthermore, in other embodiments, at least a part of the steps of weaving the first part 6, the second part 10, and the sacrificial yarn 12 to the first part 6 and the second part 10 could be carried out substantially simultaneously.

As shown in Figs. 4 and 5 the first part 6 and the second part 10 of the textile 1 are single sheets, or layers, of the textile 1. In this embodiment, the first part 6 and the second part 10 of the textile 1 are substantially planar, or substantially flat. The first part 6 and the second part 10 of the textile 1 are arranged to form a double layer scarf 2. It will be understood that further parts of the textile 1 could be added, and a two layer version is illustrated and described here for brevity.

The first part 6 of the textile 1 forms an outer layer 1a of the textile 1 and the second part 10 of the textile 1 forms an outer layer 1 a of the textile 1.

The first part 6 of the textile 1 and the second part 10 of the textile 1 are arranged opposite each other and are opposing layers of the textile 1.

In the embodiments illustrated and described here, the first part 6 is arranged to overlay the second part 10. Substantially all of the first part 6 of the textile 1 is arranged to substantially overlay substantially all of the second part 10 of the textile 1. As shown in the textile of Figs. 4 and 5, and in the other textile 1 of Fig. 9, more than one type of first yarn 4 is used to weave the first part 6 of the textile 1 , which is used to provide different regions of colour on the first part 6. Similarly, two or more second yarns 8 are used to weave the second part 10 of the textile 1. The first yarn 4 is not the same as the second yarn 6, although in other embodiments the first and second yarn 4, 6 could be the same yarn. One of the advantages of the present invention is that, because the sacrificial yarn 12 is used to connect the first part 6 to the second part 10, the textile 1 can be processed more consistently and effectively. If the first part 6 was woven directly to the second part 10, the colour of the first yarn would be visible on the second part, and vice versa, whereas the sacrificial yarn, once removed, means that there can be a separation between the first part 6 and the second part 10, which means there is the possibility of excluding the yarn from one part on another part of the textile 1. As will also be described in more detail below, the first part 6 and the second part 10 are directly woven together at two regions of the textile 1 , to hold the first part 6 and the second part 10 together, but for the majority of the finished textile 1 the colour on each of the first and second parts 6, 10, is smooth and unblemished by the weaving process.

In this embodiment, a single type of sacrificial yarn 12 is used in the step of weaving the sacrificial yarn 12 to the first part 6 and the second part 10 of the textile 1.

The first yarn 4 is provided from one or more sources of first yarn 4, the second yarn 8 is provided from one or more sources of second yarn 8, and the sacrificial yarn 12 is provided from one or more sources 12a of sacrificial yarn 12 (as shown in Fig. 8). In this embodiment, the step of weaving the sacrificial yarn 12 includes weaving a plurality of sacrificial yarns 12 (which in this embodiment are substantially identical) to the first part 6 of the textile 1 and to the second part 10 of the textile 1.

Each source 12a of sacrificial yarn 12 is different to the one or more sources of first yarn 4 and the one or more sources of second yarn 8. This is advantageous as the sacrificial yarn 12 is typically woven to the textile 1 with a high warp to weft rate in comparison to the warp to weft rate of the first yarn 4 and the second yarn 8. It is therefore advantageous to have independent control of the tension of the sacrificial yarn 12, as it may need to be under more (or less) tension than the first yarn 4 or the second yarn 8.

The method comprises the step of placing the sacrificial yarn 12 under tension prior to the step of weaving the sacrificial yarn 12 to the first part 6 and the second part 10 of the textile 1. Fig. 2 illustrates the warp sacrificial yarn 12 under tension, and Fig. 3 shows the arrangement of the warp sacrificial yarn 12.

As is conventional in weaving, the method also comprises the step of placing the first yarn 4 and the second yarn 8 under tension, and it is the warp yarns that are tensioned. The first yarn 4 is used for warp and weft yarns of the first part 6, and the second yarn 8 is used for warp and weft yarns of the second part 6. The method comprises the step of arranging the first yarn 4 in a warp direction and arranging the second yarn 8 in a warp direction, prior to beginning the weaving steps. The first yarn 4 is then arranged in the weft direction, over and under the warp first yarns during weaving, to weave the first part 6, as is known in the art of weaving. Likewise, the second yarn 8 is arranged in the weft direction over and under the warp second yarns to weave the second part 10.

In the embodiments illustrated and described here, the sacrificial yarn 12 is independently tensioned relative to the first yarn 4 and the second yarn 8 (specifically the warp yarns thereof).

The sacrificial yarn 12 is formed of a material that is different to the first yarn 4 and/or the second yarn 8. In this embodiment, the sacrificial yarn 12 is made from natural white polyester, and the first and second yarns 4,

8, are cashmere yarns. Any suitable yarns can be used.

In this embodiment, the sacrificial yarn 12 has a Tex of 12, a Ticket of 200, a strength of 920 cN, an elongation (min - max) of 16% to 22%, and a needle size (metric) of between 65 and 75. In other embodiments, it will be understood that a different sacrificial yarn 12, or yarns, could be used. For example, the sacrificial yarn 12 could be biodegradable, or non-plastic. The sacrificial yarn could be formed from one or more naturally occurring materials. The sacrificial yarn 12 could have different properties than those described here, such as different strength, elongation, Tex, etc, with the example provided here being illustrative only.

The sacrificial yarn 12 is a substantially different yarn to the first yarn 4 and the second yarn 8. In other embodiments, the sacrificial yarn 12 could be substantially the same yarn as the first yarn 4 and/or the second yarn 8.

In this embodiment, the sacrificial yarn 12 is water-insoluble. However, in other embodiments the sacrificial yarn 12 could be water-soluble. As shown in Figs. 1 to 3, the sacrificial yarn 12 has a different appearance to the first yarn 4 and the second yarn 8, as it is a different colour to the first and second yarns 4, 8, which makes it easier to identify, and makes it easier to ensure that the correct yarn is removed from the textile 1.

The sacrificial yarn 12 is a non-fibrous yarn, while the first yarn 4 and the second yarn 8 are fibrous yarns. This is advantageous as it reduces the likelihood of the sacrificial yarn 12 being caught, or snagged, in the first or second yarns 4, 8, and thus makes the removal process more efficient and less likely to damage the finished textile 1 , fabric, or garment.

The method comprises the step of arranging the sacrificial yarn 12 in a warp direction, prior to beginning the weaving steps. The warp sacrificial yarns are arranged in the same way as the first warp yarns and the second warp yarns, and during weaving, the sacrificial warp yarns are moved in such a way that the sacrificial yarn 12 is then woven to the first part 6 and the second part 10. Weaving the sacrificial yarn 12 by arranging the sacrificial yarn 12 in the warp direction is advantageous, as this is the direction of movement of the textile 1 when processed, and therefore the sacrificial yarn 12 is less likely to snag or be pulled by the movement of the textile 1 through an apparatus (e.g. when the textile 1 is moved along rollers).

In an alternative embodiment, as shown in Figs. 6 and 7, the method comprises the step of arranging the sacrificial yarn 12 in a weft direction, rather than a warp direction. The step of arranging the sacrificial yarn 12 in the weft direction is carried out during the step of weaving the sacrificial yarn 12. In this alternative embodiment, the sacrificial yarn 12 is woven to the first part 6 and the second part 10 by control of the warp first yarns 4 and the warp second yarns 8. In other embodiments, a combination of warp and weft sacrificial yarns 12 could be used.

In the embodiments illustrated and described here, a plurality of strands of the sacrificial yarn 12 are arranged in the warp direction (shown in Figs. 1 to 3) or in the weft direction (shown in Figs. 6 and 7). In other embodiments, it may be sufficient to use a single strand of sacrificial yarn 12, and in some embodiments it may be desirable to arrange the sacrificial yarn 12 in the warp and weft directions.

In the embodiment shown in Figs. 1 to 3, the sacrificial yarn is woven to the first part 6 of the textile 1 and the second part 10 of the textile 1 at a ratio of warp to weft of between 75:1 and 120:1, which means that the sacrificial yarn 12 crosses one weft yarn in every 76 to 121 weft yarns of the first part 6 of the textile 1 , and the sacrificial yarn crosses the weft yarns of the second part 10 of the textile in the same ratio. In the embodiment shown in Figs. 6 and 7, the ratio is between 200:1 and 300:1 , which means that one warp first yarn crosses the weft sacrificial yarn in every 201 to 301 first yarns, and likewise one warp second yarn 8 crosses the weft sacrificial yarn 12 in every 201 to 301 second yarns.

In the embodiments illustrated and described here, the sacrificial yarn 12 is arranged independently of the first yarn 4 and of the second yarn 8.

The sacrificial yarn 12 can be arranged independently in the warp direction and/or the weft direction, depending on how the sacrificial yarn 12 is to be woven. The sacrificial yarn 12 is a separate yarn from the first yarn 4 and the second yarn 8.

Fig. 9 shows a finished textile 1 produced using the method of the present invention. With reference to Fig. 9, the step of weaving the sacrificial yarn to the first and second parts 6, 10, of the textile 1 can include weaving the sacrificial yarn 12 to at least one of: a mid region 3a, a central region 3b, one or more end regions 3c, one or more horizontal end regions 3d, one or more vertical end regions 3e, one or more upper regions 3f, one or more mid-upper regions 3f , one or more mid-lower regions 3g’, one or more lower regions 3g, one or more side regions 3h, one or more right side regions 3h’, one or more left side regions 3h”, one or more mid-side regions 3i, and one or more border regions 3j of the first part 6 and the second part 10 of the textile 1.

Still with reference to Fig. 9, the border regions 3j, at the right side and left side of the textile 1 , have been woven together using the first and second yarns 4, 8. In other embodiments, the mid region 3a is woven together using the first and second yarns 4, 8 (shown in Figs. 10 and 11), and the sacrificial yarn 12 used to hold the rest of the textile 1 together during processing thereof. The sacrificial yarn 12 can then be removed, leaving the mid region 3a as the only permanent weave between the first and second parts 6, 10, of the textile 1. Other possible arrangements of the permanent weave between the first and second parts 6, 10, and the use of the sacrificial yarn 12, will be apparent to those of skill in the art.

The step of weaving the sacrificial yarn 12 to the first and second parts 6, 10, of the textile 1 comprises weaving the sacrificial yarn 12 at a plurality of regions of the first part 6 and the second part 10 of the textile 1. The method comprises a plurality of steps of guiding, or moving, the sacrificial yarn 12 independently of the first yarn 4 and/or the second yarn 8 during the step of weaving the sacrificial yarn 12. The guiding or moving of the sacrificial yarn 12 may be carried out in accordance with any suitable weaving technique. In the embodiments illustrated and described here, a heddle is used to guide the sacrificial yarn 12. The first yarn 4 and the second yarn 8 each have their own heddles for guiding their movement during the weaving process. Turning now to the weaving of the first part 6 to the second part 10, in the embodiments illustrated and described here, the step of weaving at least a portion of the first part 6 of the of the textile 1 to at least a portion of the second part 10 of the textile 1 comprises the step of weaving the first yarn 4 directly to the second yarn 10 at two end regions 3c of the textile 1 (shown in Figs. 4 and 5), although any suitable regions could be woven together in this manner.

The step of weaving the first yarn 4 directly to the second yarn 8 is carried out substantially simultaneously to the steps of weaving the sacrificial yarn 12 to the first part 6 and the second part 10 of the textile 1 , and to the steps of weaving the first part 6 and the second part 10 of the textile 1. These direct weaves between the first yarn 4 and the second yarn 8 are designed to hold the textile 1 together once the sacrificial yarn 12 has been removed.

The step of weaving the first yarn 4 to the second yarn 8 could be carried out by weaving a further yarn to the first part 6 and the second part 10 of the textile 1. The further yarn could be different to the sacrificial yarn 12. As shown in figs. 4 and 5 the step of weaving at least a portion of the first part 6 of the of the textile 1 to at least a portion of the second part 10 of the textile 1 includes weaving the first yarn 4 to the second yarn 8 at a plurality of horizontal end regions 3d. This step could include weaving the first yarn 4 to the second yarn 8 at at least one of: a mid region 3a, a central region 3b, one or more end regions 3c, one or more horizontal end regions 3d, one or more vertical end regions 3e, one or more upper regions 3f, one or more mid-upper regions 3f , one or more mid-lower regions 3g’, one or more lower regions 3g, one or more side regions 3h, one or more right side regions 3h’, one or more left side regions 3h”, one or more mid-side regions 3i, and one or more border regions 3j of the first part 6 and the second part 10 of the textile 1.

The step of weaving at least a portion of the first part 6 of the of the textile 1 to at least a portion of the second part 10 of the textile 1 includes weaving the first yarn 4 to the second yarn 8 at a plurality of regions of the first part 6 and the second part 10 of the textile 1 , however in other embodiments only one region may be sufficient. Turning now to the removal of the sacrificial yarn 12, in this embodiment substantially all of the sacrificial yarn 12 is removed from the textile 1. It will be appreciated that in other embodiments, it may be sufficient to remove a portion of the sacrificial yarn 12 from the textile 1. The step of removing the sacrificial yarn 12 is carried out separately to and after the weaving steps of the method of the present invention, and using a manual process. In this embodiment, the step of removing the sacrificial yarn 12 from the textile 1 is carried out by hand, but other manual processes could be used, such as mechanical removal of the sacrificial yarn 12 using a machine. The step of removing the sacrificial yarn 12 from the textile 1 is carried out by pulling each of the strands of the sacrificial yarn 12 from the textile 1. The method thus comprises a plurality of sacrificial yarn 12 removal steps, each removal step removing at least a portion of the sacrificial yarn 12 from the textile 1. It will be understood that removing the sacrificial yarn 12 by hand can be done directly by hand, or by using a hand tool, or the like. Removal of the sacrificial yarn 12 by hand is advantageous as it mitigates damage to the textile 1 and avoids the need for heat/chemical treatment to be used. The step of removing the sacrificial yarn 12 includes removing the sacrificial yarn 12 substantially intact. The sacrificial yarn 12 once removed from the textile 1 , can be used in a further method of producing a textile. The sacrificial yarn 12 is substantially unmodified after removal from the textile 1. Each sacrificial yarn 12 removal step is a non- destructive removal step that is non-destructive to substantially all of the first yarn 4, the second yarn 8, and the sacrificial yarn 12 itself.

The, or each, step of removing at least a portion of the sacrificial yarn 12 from the textile 1 creates, or enlarges, one or more openings 16 (shown in Fig. 5) between the first part 6 of the textile 1 and the second part 10 of the textile 1.

Each step of removing at least a portion of the sacrificial yarn 12 from the textile 1 detaches at least a portion of the first part 6 of the textile 1 from at least a portion of the second part 10 of the textile 1.

The method typically comprises one or more textile processing steps, although these are not essential to implement the invention. One or more textile processing steps may be carried out between the weaving steps and the step of removing at least a portion of the sacrificial yarn 12 from the textile 1. The textile processing steps can include one or more weaving steps, or weaving finishing steps.

The first part 6 and the second part 10 of the textile 1 are woven using one or more weave patterns, typically a plain weave, although any suitable weaving pattern may be used.

The step of weaving the sacrificial yarn 12 to the first part 4 and the second part 8 of the textile 1 is carried out using one or more weave patterns. The weave pattern may be an offset weave pattern, or the like.

A weaving apparatus 14 is operable to automatically carry out the weaving steps of the method. Any one or all of the weaving steps can be carried out using a dobby weave, or a jacquard weave, or any suitable weave.

Fig. 10 and Fig. 11 show an alternative embodiment of the invention, in which the first part 6 and the second part 10 of the textile 1 are woven together at a mid region 3a. The majority of the first part 6 and the second part 10 are unwoven to each other (after removal of the sacrificial yarn 12). The sacrificial yarn 12 allows the first and second parts 6, 10 to be held together during weaving, and the resultant textile 1 shown in Fig. 10 (front view) and Fig. 11 (rear view) has openings 16 all around its perimeter.

More detail on the how the invention can be carried out is outlined below.

Typically, a digital visual artwork is created, and a digital weaving file is encoded with the following technical information: (a) Yarn types, such as count, twist, composition, colour.

(b) Warp sett (density of warp yarns - this parameter is defined by the loom types).

(c) Pick rate (density of weft yarns - this is a flexible parameter). (d) Loom set-up (overall width of cloth, number of units across, selvedge, cutting gaps, fringes).

(e) Dobby warp pattern or draft.

(f) Either: use a dobby peg plan to create weave structure - (peg plan is the pattern or sequence of lifts for the yarns on the loom shafts); or use a jacquard weave disc.

The warp is made to the defined length which will vary according to the quantity of textile 1 required. The warp is put onto a beam, which is loaded into the back of the loom and the threads are knotted in and pulled through the heddles (e.g. a needle-like structure that holds an individual thread in place) to the front of the loom. The sacrificial yarn 12 is kept separate to the warp first and second yarns 4, 8, which are on the beam in loom.

In this detailed embodiment, the sacrificial yarn 12 is 1/83 count natural white polyester. This is not the only sacrificial yarn 12 that it would be possible to use. The sacrificial yarn 12 has the following features:

(a) It can be easily removed at the end of the process and with minimal disturbance to the base fabric.

(b) It is fine enough to sit between the other woven yarns without pushing them apart or causing visual distortion (which would be apparent as holes once the yarn has been removed). (c) It will withstand the weaving and finishing processes without being damaged. For example, it will not snap under tension or dissolve at high temperatures. A single end of sacrificial yarn 12 is fed from an individual cone (an example of a source 12a of sacrificial yarn 12) at the back of the loom on the floor (shown in Fig. 8).

This single end of sacrificial yarn 12 is fed by hand from its cone on the floor, up into its own heddle and through to the front of the loom. This heddle now securely holds the single end of sacrificial yarn 12 in position, running in the same direction as the warp threads on the beam.

Keeping the sacrificial yarn 12 separate to the warp allows for more flexibility in weave structure, as the warp is typically placed under an even tension. A separate cone of sacrificial yarn 12 can have a different tension, which allows for weaving the sacrificial yarn 12 at a different rate to the warp first and second yarn 4, 8 threads without causing tension or ‘take-up’ issues. A take-up issue would create loose threads (if a thread is woven less often than other warp threads) or tight threads (if woven more often than other warp threads). This could then either create weaving difficulties while in loom, such as snapping threads, or could cause visible defects in the final product. The sacrificial yarn 12 could be used in the weft, but the benefits to using it in the warp include:

(a) If the product is woven in ‘portrait’ format i.e. longer than it is wide, having the sacrificial yarn 12 in the warp means that at the final stage, when the sacrificial thread is removed by hand, fewer, longer threads are removed as opposed to removing more short sacrificial yarn threads 12. It is therefore faster to remove the sacrificial yarn 12 when arranged in the warp direction.

(b) There is a limit of eight weft feeders or selectors on the weaving apparatus 14. It would restrict the number of colours that could be woven in the weft if one or more selectors were used for the sacrificial yarn 12.

The number of single ends of sacrificial yarn 12 fed into a design is dependent on the size of the weaving apparatus 14. In this embodiment, all sacrificial yarns 12 are spaced out the same distance from one another, horizontally along the back of the loom (when the sacrificial yarn 12 is arranged in warp) or vertically (when the sacrificial yarn 12 is used in weft). The peg plan pattern is programmed into the dobby loom, which will tell the shafts what to do, creating the main fabric design and dictating when the sacrificial yarn 12 weaves into the first part 6 and the second part 10 of the textile 1. The first and second yarns 4, 8, arranged in the warp are fine in yarn count, and therefore result in a lightweight/delicate textile 1. The loom is fitted with a temple bar which helps to hold the lightweight textile 1 down and to keep the textile 1 straight (horizontally) at the ‘fell’ point where the warp yarns are interweaving with the weft yarns.

The sacrificial yarn 12 is woven into the textile 1 in such a way as to hold the first and second parts 6, 10 together. In this detailed example, the sacrificial yarn 12 weaves in an offset pattern. The spacing between sacrificial yarns 12 can vary depending on the properties of the textile 1. Spacings of approximately 21 cm, or approximately 7cm (from warp yarn to warp yarn) are effective, but any suitable spacing can be used.

After weaving is complete, the textile 1 is cut out of the loom and the roll of textile 1 is inspected for knots, broken threads, or other flaws and defects.

The finishing steps applied to the textile 1 can include the following.

Scour is a wet finishing stage and follows a standard programme developed to dissolve supporting polyvinyl acetate (PVA). PVA is used with fine cashmere of the first yarn 4 and the second yarn 8 to assist the weaving process. Any suitable scouring programme, if required, can be used according to the specification of the yarn used.

A tenter process (dried under tension for width) involves drying the textile 1 in such a way as to remove creases and give stability to the dimensions. An inspection is then typically carried out, to checking the condition of the textile 1 , such as checking for faults, and pulling threads at the fringes to make the fringes neat (but not touching the sacrificial yarn 12 at this stage). Hand slitting is used to cut the textile 1 apart in a vertical direction. This is specific to the size of the textile 1 used in the embodiments illustrated and described here.

Once the finishing steps are applied, the sacrificial yarn 12 is carefully pulled out from the textile 1 by hand. Modifications and improvements may be made to the foregoing embodiments without departing from the scope of the present invention. For example, the step of weaving the sacrificial yarn 12 to the first and second parts 6, 10 of the textile 1 can comprise a plurality of steps of weaving the sacrificial yarn 12 to the first and second parts of the textile.

At least a part of the step of weaving the first yarn 4 to produce the first part 6 of the textile may be carried out substantially simultaneously to at least a part of the step of weaving the second yarn 8 to produce the second part 10 of the textile 1.

At least a part of the step of weaving the first yarn 4 to produce the first part 6 of the textile 1 can be carried out substantially simultaneously to the step of weaving the sacrificial yarn 12 to the first part 6 of the textile 1 and the second part 10 of the textile 1.

At least a part of the step of weaving the second yarn 8 to produce the second part 10 of the textile 1 can be carried out substantially simultaneously to the step of weaving the sacrificial yarn 12 to the first part 6 of the textile 1 and the second part 10 of the textile 1.




 
Previous Patent: APPARATUS WITH FLEXIBLE CONNECTOR

Next Patent: SODIUM-ION CELLS