A three-dimensional multilayer fabric is provided. The fabric comprises a surface layer, a backing layer, and an intermediate layer connecting the surface layer and the backing layer. The surface layer includes sequential unstitched surface portions and sequential stitched surface portions formed in
A three-dimensional multilayer fabric is provided. The fabric comprises a surface layer, a backing layer, and an intermediate layer connecting the surface layer and the backing layer. The surface layer includes sequential unstitched surface portions and sequential stitched surface portions formed in an alternating and repeating pattern. The unstitched surface portions of the surface layer are essentially composed of surface warp threads only, and the stitched surface portions of the surface layer are composed of the surface warp threads and intermediate warp threads. The backing layer includes sequential unstitched backing portions and sequential stitched backing portions formed in an alternating and repeating pattern. The unstitched backing portions of the backing layer are essentially composed of backing warp threads only, and the stitched backing portions of the backing layer are composed of the backing warp threads and the intermediate warp threads. The intermediate warp threads are woven without interlacing with weft threads on the surfaces of the unstitched backing portions. The intermediate layer includes sequential intermediate portions composed of the intermediate warp threads only. Each of the intermediate portions consists of a first intermediate portion and a second intermediate portion connected to the stitched surface portions and the stitched backing portions in an alternating and repeating pattern. The connecting warp threads of the intermediate layer exposed to the outside of the backing layer are sheared. Further provided is a method for the production of the fabric.
대표청구항▼
The invention claimed is: 1. A three-dimensional multilayer fabric, comprising a surface layer, a backing layer and an intermediate layer connecting the surface layer and the backing layer wherein the surface layer includes sequential unstitched surface portions and sequential stitched surface port
The invention claimed is: 1. A three-dimensional multilayer fabric, comprising a surface layer, a backing layer and an intermediate layer connecting the surface layer and the backing layer wherein the surface layer includes sequential unstitched surface portions and sequential stitched surface portions formed in an alternating and repeating pattern, the unstitched surface portions being essentially composed of surface warp threads only and the stitched surface portions being composed of the surface warp threads and intermediate warp threads; the backing layer includes sequential unstitched backing portions and sequential stitched backing portions formed in an alternating and repeating pattern, the unstitched backing portions being essentially composed of backing warp threads only and the stitched backing portions being composed of the backing warp threads and the intermediate warp threads; and the intermediate layer includes sequential intermediate portions composed of the intermediate warp threads only, each of the intermediate portions consisting of a first intermediate portion and a second intermediate portion connected to the stitched surface portions and the stitched backing portions in an alternating and repeating pattern, the intermediate warp threads being woven without interlacing with weft threads on the surfaces of the unstitched backing portions and exposed to the outside, followed by shearing. 2. The three-dimensional fabric according to claim 1, wherein each of the first and second intermediate portions of the intermediate layer is connected to the corresponding stitched surface portion and the subsequent stitched backing portion of the stitched backing portion lying on the same vertical line as the stitched surface portion. 3. The three-dimensional fabric according to claim 2, wherein the surface warp threads are woven with the first intermediate warp threads to form the first stitched surface portion, and the first intermediate warp threads only are woven to form the intermediate layer and are woven with the backing warp threads to form the second stitched backing portion. 4. The three-dimensional fabric according to claim 3, wherein the first intermediate warp threads are woven without interlacing with the weft threads, where the backing warp threads only are woven to form the unstitched backing portions. 5. The three-dimensional fabric according to claim 4, wherein the connecting warp threads of the first intermediate portion connect the starting point of the third stitched backing portion to the starting point of the third stitched surface portion and are woven together with the surface warp threads to form the third stitched surface portion. 6. The three-dimensional fabric according to claim 5, wherein the first stitched backing portion of the backing layer is formed at the same vertical position as the first stitched surface portion and is composed of the backing warp threads and the second intermediate warp threads, and the second intermediate warp threads are woven without interlacing with the weft threads. 7. The three-dimensional fabric according to claim 6, wherein the connecting warp threads of the second intermediate portion are woven together with the surface warp threads at the starting point of the second stitched backing portion to form the second stitched surface portion of the surface layer. 8. The three-dimensional fabric according to claim 7, wherein the second intermediate warp threads having participated in the formation of the second stitched surface portion are woven to form the second intermediate portion and are woven together with the backing warp threads to form the third stitched backing portion. 9. A three-dimensional fabric, comprising a surface layer, a backing layer and an intermediate layer connecting the surface layer and the backing layer wherein the surface layer includes sequential unstitched surface portions and sequential stitched surface portions, the backing layer includes sequential unstitched backing portions and sequential stitched backing portions, and the intermediate layer includes sequential intermediate portions, each consisting of a first intermediate portion and a second intermediate portion; and wherein when surface warp threads are 1/3, backing warp threads are 2/4, first intermediate warp threads are 5/7 and second intermediate warp threads are 6/8, as indicated by harness numbers, the unstitched surface portions and the unstitched backing portions are essentially composed of 1/3 and 2/4, respectively, the first and third stitched surface portions are composed of 1/3/5/7, and the second stitched surface portion is composed of 1/3/6/8, the first and third stitched backing portions of the baking layer are composed of 2/4/6/8, the second stitched backing portion is composed of 2/4/5/7, and the first and second intermediate portions are composed of 5/7 and 6/8, respectively, the connecting warp threads of the intermediate layer exposed to the outside of the backing layer being sheared. 10. A method for the production of a three-dimensional multilayer fabric comprising a surface layer, a backing layer and an intermediate layer connecting the surface layer and the backing layer, the method comprising the steps of: interlacing surface warp threads and intermediate warp threads with weft threads while shedding along a harness to form a stitched surface portion; interlacing backing warp threads and the intermediate warp threads with the weft threads during shedding to form a stitched backing portion; interlacing the surface warp threads with the weft threads to form an unstitched surface portion; interlacing the intermediate warp threads with the weft threads to form the intermediate layer; interlacing the backing warp threads with the weft threads to form an unstitched backing portion; and sequentially repeating the above procedure as the pre-designed length and shearing the connecting warp threads of the intermediate layer exposed to the outside of the backing layer. 11. The method according to claim 10, wherein the intermediate layer includes sequential intermediate portions, each consisting of a first intermediate portion and a second intermediate portion, and in the step of forming the stitched surface portion, the surface warp threads and first intermediate warp threads are interlaced with the weft threads while shedding along the harness to form the first stitched surface portion. 12. The method according to claim 11, wherein, in the step of forming the stitched backing portion, the backing warp threads and second intermediate warp threads are interlaced with the weft threads during shedding to form the second stitched backing portion. 13. The method according to claim 12, wherein the step of forming the intermediate layer includes the sub-step of interlacing the first intermediate warp threads with the weft threads to form the first intermediate portion. 14. The method according to claim 13, wherein the step of forming the stitched surface portion includes the sub-step of weaving the second intermediate warp threads with the surface warp threads to form the second stitched surface portion. 15. The method according to claim 14, wherein the step of forming the stitched backing portion includes the sub-step of weaving the first intermediate warp threads with the backing warp threads to form the second stitched backing portion. 16. A method for the production of a three-dimensional multilayer fabric comprising a surface layer, a backing layer, and an intermediate layer connecting the surface layer and the backing layer and including sequential intermediate portions, each of the intermediate portions consisting of a first intermediate portion and a second intermediate portion, the method comprising the steps of: weaving surface warp threads with first intermediate warp threads to form a first stitched surface portion and weaving the first intermediate warp threads only to form the first intermediate portion; weaving backing warp threads with second intermediate warp threads to form a first stitched backing portion at the same vertical position as the first stitched surface portion, and weaving the second intermediate warp threads without interlacing with the weft threads, where the backing warp threads only are interlaced with the weft threads to form the backing layer; weaving the connecting warp threads of the second intermediate portion with the surface warp threads at the starting point of a second stitched backing portion to form a second stitched surface portion of the surface layer, and weaving the second intermediate warp threads only to form the second intermediate portion; weaving the first intermediate warp threads with the backing warp threads to form a second stitched backing portion and weaving the first intermediate warp threads without interlacing with the weft threads, where the backing warp threads only are woven to form unstitched backing portions; and shearing the connecting warp threads of the intermediate layer exposed to the outside of the backing layer. 17. The method according to claim 16, wherein when the surface warp threads are 1/3, the backing warp threads are 2/4, the first intermediate warp threads are 5/7 and the second intermediate warp threads are 6/8, as indicated by harness numbers, the unstitched surface portion and the unstitched backing portion are essentially composed of 1/3 and 2/4, respectively, the first and third stitched surface portions are composed of 1/3/5/7, and the second stitched surface portion is composed of 1/3/6/8, the first and third stitched backing portions of the baking layer are composed of 2/4/6/8, the second stitched backing portion is composed of 2/4/5/7, and the first and second intermediate portions are composed of 5/7 and 6/8, respectively. 18. A three-dimensional multilayer fabric, comprising a surface layer, a backing layer and an intermediate layer connecting the surface layer and the backing layer wherein the surface layer includes sequential unstitched surface portions and sequential stitched surface portions formed in an alternating and repeating pattern, the unstitched surface portions being essentially composed of surface warp threads only and the stitched surface portions being composed of the surface warp threads and intermediate warp threads; the backing layer includes sequential unstitched backing portions and sequential stitched backing portions formed in an alternating and repeating pattern, the unstitched backing portions being essentially composed of backing warp threads only and the stitched backing portions being composed of the backing warp threads and the intermediate warp threads; and the intermediate layer includes sequential intermediate portions composed of the intermediate warp threads only, each of the intermediate portions consisting of a first intermediate portion and a second intermediate portion connected to the stitched surface portions and the stitched backing portions in an alternating and repeating pattern, the intermediate warp threads being woven without interlacing with weft threads on the surfaces of the unstitched backing portions and the unstitched surface portions and exposed to the outside, followed by shearing. 19. A method for the production of a three-dimensional multilayer fabric comprising a surface layer, a backing layer and an intermediate layer connecting the surface layer and the backing layer, the method comprising the steps of: interlacing surface warp threads and intermediate warp threads with weft threads while shedding along a harness to form a stitched surface portion; interlacing backing warp threads and the intermediate warp threads with the weft threads during shedding to form a stitched backing portion; interlacing the surface warp threads with the weft threads to form an unstitched surface portion; interlacing the intermediate warp threads with the weft threads to form the intermediate layer; interlacing the backing warp threads with the weft threads to form an unstitched backing portion; weaving the intermediate warp threads having participated in the formation of the stitched backing portion without interlacing with the weft threads and moving the intermediate warp threads from any point of the unstitched backing portion to the unstitched surface portion; and sequentially repeating the above procedure as the pre-designed length and shearing the connecting warp threads of the intermediate layer exposed to the outside of the backing layer and the surface layer. 20. A method for the production of a three-dimensional multilayer fabric comprising a surface layer, a backing layer, and an intermediate layer connecting the surface layer and the backing layer and including sequential intermediate portions, each consisting of a first intermediate portion and a second intermediate portion, the method comprising the steps of: weaving surface warp threads with first intermediate warp threads to form a first stitched surface portion and weaving the first intermediate warp threads only to form the first intermediate portion; weaving backing warp threads with second intermediate warp threads to form a first stitched backing portion at the same vertical position as the first stitched surface portion, weaving the second intermediate warp threads without interlacing with weft threads, where the backing warp threads only are interlaced with the weft threads to form an unstitched backing portion, and moving the second intermediate warp threads upwardly from any point of the unstitched backing portion to the surface layer; moving the connecting warp threads of the second intermediate portion upwardly from any point of the unstitched backing portion between the first stitched surface portion and the second stitched surface portion to the unstitched surface portion, weaving the connecting warp threads without interlacing with the weft threads, weaving the connecting warp threads with the surface warp threads at the starting point of the second stitched backing portion to form a second stitched surface portion of the surface layer, and weaving the second intermediate warp threads only to form the second intermediate portion; weaving the first intermediate warp threads with the backing warp threads to form a second stitched backing portion, weaving the first intermediate warp threads without interlacing with the weft threads, and weaving the backing warp threads only to form an unstitched backing portion till the starting point of a subsequent stitched backing portion; and shearing the connecting warp threads of the intermediate layer exposed to the outside of the backing layer and the surface layer. 21. The method according to claim 20, wherein when the surface warp threads are 1/3, the backing warp threads are 2/4, the first intermediate warp threads are 5/7 and the second intermediate warp threads are 6/8, as indicated by harness numbers, the unstitched surface portion and the unstitched backing portion are essentially composed of 1/3 and 2/4, respectively, the first and third stitched surface portions are composed of 1/3/5/7, and the second stitched surface portion is composed of 1/3/6/8, the first and third stitched backing portions of the baking layer are composed of 2/4/6/8, the second stitched backing portion is composed of 2/4/5/7, and the first and second intermediate portions are composed of 5/7 and 6/8, respectively. 22. A three-dimensional multilayer fabric, comprising a surface layer, a backing layer and an intermediate layer connecting the surface layer and the backing layer wherein the surface layer includes sequential unstitched surface portions and sequential stitched surface portions formed in an alternating and repeating pattern, the unstitched surface portions being essentially composed of surface warp threads only and the stitched surface portions being composed of the surface warp threads and intermediate warp threads; the backing layer includes sequential unstitched backing portions and sequential stitched backing portions formed in an alternating and repeating pattern, the unstitched backing portions being essentially composed of backing warp threads and the intermediate warp threads; and the intermediate layer includes sequential intermediate portions composed of the intermediate warp threads only, each of the intermediate portions consisting of a first intermediate portion and a second intermediate portion connected to the stitched surface portions and the stitched backing portions in an alternating and repeating pattern, the intermediate warp threads being interlaced with extra weft threads on the surface layer to form protruding portions exposed to the outside, after which the protruding portions are removed to create a three-dimensional shape. 23. The three-dimensional fabric according to claim 22, wherein each of the first and second intermediate portions of the intermediate layer is connected to the corresponding stitched surface portion and the subsequent stitched backing portion of the stitched backing portion lying on the same vertical line as the stitched surface portion. 24. The three-dimensional fabric according to claim 23, wherein the surface warp threads only are woven without weaving with the other warp threads to form the unstitched surface portions and are woven with second intermediate warp threads to form the second stitched surface portion. 25. The three-dimensional fabric according to claim 24, wherein the second intermediate warp threads only are woven to form the second intermediate portion and are woven together with the surface warp threads to form the second stitched surface portion. 26. The three-dimensional fabric according to claim 25, wherein the second intermediate warp threads having participated in the formation of the stitched surface portion are exposed to the upper surface of the surface layer and two extra weft threads are woven upwardly and downwardly with respect to the warp threads to surround the warp threads. 27. The three-dimensional fabric according to claim 26, wherein the warp threads having participated in the formation of the protruding portions are moved to the backing layer and are woven together with the backing warp threads to form the unstitched backing portion (zone B) and the third stitched backing portion from the point where the formation of the second stitched backing portion is completed. 28. The three-dimensional fabric according to claim 27, wherein the backing warp threads are woven with first intermediate warp threads to form the unstitched backing portion (zone A) and the second stitched backing portion. 29. The three-dimensional fabric according to claim 28, wherein the first intermediate warp threads only are woven to form the first intermediate portion and the surface warp threads are woven with the first intermediate warp threads to form the third stitched surface portion. 30. The three-dimensional fabric according to claim 29, wherein the first intermediate warp threads having participated in the formation of the unstitched portion are exposed to the upper surface of the surface layer and two extra weft threads are woven upwardly and downwardly with respect to the warp threads to surround the warp threads. 31. The three-dimensional fabric according to claim 30, wherein the warp threads having participated in the formation of the protruding portions are moved to the backing layer and are woven together with the backing warp threads to form the unstitched backing portion and the stitched backing portion from the point where the formation of the third stitched backing portion is completed. 32. A three-dimensional fabric, comprising a surface layer, a backing layer and an intermediate layer connecting the surface layer and the backing layer wherein the surface layer includes sequential unstitched surface portions and sequential stitched surface portions, the backing layer includes sequential unstitched backing portions and sequential stitched backing portions, and the intermediate layer includes sequential intermediate portions, each consisting of a first intermediate portion and a second intermediate portion; and wherein when surface warp threads are 1/3, backing warp threads are 2/4, first intermediate warp threads are 5/7 and second intermediate warp threads are 6/8, as indicated by harness numbers, the surface layer is composed of 1/3, the first and third stitched surface portions are composed of 1/3/5/7, the second stitched surface portion is composed of 1/3/6/8, the unstitched backing portion till the first stitched backing portion and the stitched portion are composed of 2/4/6/8, the unstitched backing portion till the second stitched backing portion and the stitched portion are composed of 2/4/5/7, the unstitched backing portion till the third stitched backing portion and the stitched portion are composed of 2/4/6/8, the above procedure is sequentially repeated, and protruding portions exposed to the outside of the surface layer are removed. 33. The three-dimensional fabric according to claim 1, wherein the warp thread and/or the weft thread is woven with a low-melting point yarn. 34. The three-dimensional fabric according to claim 33, wherein the low-melting point yarn is a grey yarn whose melting point is intentionally lowered by modification of molecular structure, copolymerization, blending, spinning process control or composite spinning so that the surface is allowed to be minutely fused by thermal treatment in the temperature range of about 120° C. to about 190° C. 35. The three-dimensional fabric according to claim 1, wherein the fabric is further thermally treated before or after the shearing or before or after removal of the protruding portions exposed to the outside of the backing layer to achieve improved shape stability and enhanced stiffness. 36. The three-dimensional fabric according to claim 1, wherein the intermediate layer is denser than the surface layer and the backing layer. 37. A method for the production of a three-dimensional multilayer fabric comprising a surface layer, a backing layer and an intermediate layer connecting the surface layer and the backing layer, the method comprising the steps of: weaving surface warp threads only to form a stitched surface portion; weaving intermediate warp threads only to form the intermediate layer; weaving the intermediate warp threads with backing warp threads to form an unstitched backing portion; weaving the surface warp threads and the intermediate warp threads to form a stitched surface portion; weaving the intermediate warp threads with the backing warp threads to form a stitched backing portion; exposing the intermediate warp threads to the outside of the surface layer and weaving the exposed intermediate warp threads with extra weft threads to form a protruding portion; and sequentially repeating the above procedure as the pre-designed length and shearing the protruding portions exposed to the outside of the surface layer. 38. The method according to claim 37, wherein the surface warp threads are woven with second intermediate warp threads to form the second stitched surface portion. 39. The method according to claim 38, wherein the intermediate layer includes sequential intermediate portions, each consisting of a first intermediate portion and a second intermediate portion, and the first and second intermediate portions are composed of first intermediate warp threads and second intermediate warp threads, respectively. 40. The method according to claim 39, wherein the second intermediate warp threads are exposed to the upper surface of the surface layer and two extra weft threads are woven upwardly and downwardly with respect to the warp threads to surround the warp threads. 41. The method according to claim 40, wherein the second intermediate warp threads having participated in the formation of the protruding portions are moved to the backing layer and are woven together with the backing warp threads to form the unstitched backing portion (zone B) and the third stitched backing portion from the point where the formation of the second stitched backing portion is completed. 42. The method according to claim 41, wherein the backing warp threads are woven with first intermediate warp threads to form the unstitched backing portion (zone A) and the second stitched backing portion. 43. The method according to claim 42, wherein the surface warp threads are woven with the first intermediate warp threads to form the first intermediate portion. 44. The method according to claim 43, wherein the first intermediate warp threads are exposed to the upper surface of the surface layer and two extra weft threads are woven upwardly and downwardly with respect to the warp threads to surround the warp threads. 45. The method according to claim 44, wherein the warp threads having participated in the formation of the protruding portions are moved to the backing layer and are woven together with the backing warp threads to form the unstitched backing portion and the stitched backing portion from the point where the formation of the third stitched backing portion is completed. 46. A method for the production of a three-dimensional multilayer fabric comprising a surface layer, a backing layer and an intermediate layer connecting the surface layer and the backing layer wherein the surface layer includes sequential unstitched surface portions and sequential stitched surface portions, the backing layer includes sequential unstitched backing portions and sequential stitched backing portions, and the intermediate layer includes sequential intermediate portions, each consisting of a first intermediate portion and a second intermediate portion, the method comprising the steps of: weaving first intermediate warp threads (5/7) to form the first intermediate portion (5/7), weaving second intermediate warp threads (6/8) to form the second intermediate portion (6/8), weaving surface warp threads (1/3) to form the surface layer (1/3), weaving the surface warp threads (1/3) and the first intermediate warp threads (5/7) to form the first and third stitched surface portions (1/3/5/7), weaving the surface warp threads (1/3) and the second intermediate warp threads (6/8) to form the second stitched surface portion (1/3/6/8), weaving backing warp threads (2/4) and the second intermediate warp threads (6/8) to form the unstitched backing portion (2/4/6/8) till the first stitched backing portion and the stitched portion (2/4/6/8), weaving the backing warp threads (2/4) and the first intermediate warp threads (5/7) to form the unstitched backing portion (2/4/5/7) till the second stitched backing portion and the stitched portion (2/4/5/7), weaving the backing warp threads (2/4) and the second intermediate warp threads (6/8) to form the unstitched backing portion (2/4/6/8) till the third stitched backing portion and the stitched portion (2/4/6/8) [the numbers in parentheses indicate harness numbers], sequentially repeating the above procedure, and removing protruding portions exposed to the outside of the surface layer. 47. The method according to claim 10, wherein the warp thread and/or the weft thread is woven with a low-melting point yarn. 48. The method according to claim 10, wherein the fabric is further thermally treated before or after the shearing or before or after removal of the protruding portions exposed to the outside of the backing layer to achieve improved shape stability and enhanced stiffness. 49. The method according to claim 10, wherein the intermediate layer is denser than the surface layer and the backing layer.
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