Multi-Layer Woven Fabric

An air impermeable multi-layer woven fabric comprising multi-layer woven fabric having a first side and a second side and having a warp and weft direction, wherein the weft direction is perpendicular to the warp direction, and wherein the multi-layer woven fabric contains a central region and at least one outer region, wherein the central region has a starting edge area and an ending edge area in the weft direction of the multi-layer woven fabric, wherein the central region comprises:

• a first woven layer having an upper and lower surfaces and comprising a plurality of first warp yarns and first weft yarns, wherein the upper surface of the first woven layer forms the first side of the multi-layer woven fabric;
• a second woven layer having an upper and lower surfaces and comprising a plurality of second warp yarns and second weft yarns, wherein the lower surface of the second woven layer forms the second side of the multi-layer woven fabric;
• and,
• a plurality of connecting yarns, wherein the connecting yarns connect the first woven layer and the second woven layer, wherein each connecting yarn has a stitching pattern that contains a first weave section, a crossover section, and a second weave section;
• and,
• an air impermeable layer located on the first side and the second side of the multi-layer woven fabric;
• wherein within the first weave section each connecting yarn is interwoven only with the first warp yarns of the first woven layer and the first weave section begins at the starting edge area of the central region and ends at a final weave stitch with the first warp yarns of the first woven layer;
• wherein within the crossover section each connecting yarn is not interwoven with any yarns of the multi-layer woven fabric, wherein the crossover section begins at the final weave stitch with the first warp yarns of the first woven layer and ends with a first weave stitch with the second warp yarns of the second woven layer, wherein the length of connecting yarn between the final weave stitch with the first warp yarns and the first weave stitch with the second warp yarns of the second woven layer is defined as the crossover distance;
• wherein within the second weave section each connecting yarn is interwoven only with the second warp yarns of the second woven layer and the second weave section begins at the first weave stitch with the second warp yarns of the second woven layer and ends at the ending edge area of the central region;
• and
• wherein within the starting edge area of the central region essentially all of the connecting yarns are not interwoven with the second woven layer and at least a portion of the connecting yarns are interwoven with the first woven layer, and wherein within the ending edge area of the central region essentially all of the connecting yarns are not interwoven with the first woven layer and at least a portion of the connecting yarns are interwoven with the second woven layer.

An inflatable support article comprising:

• air impermeable multi-layer woven fabric comprising multi-layer woven fabric having a first side and a second side and having a warp and weft direction, wherein the weft direction is perpendicular to the warp direction, and wherein the multi-layer woven fabric contains a central region and at least one outer region, wherein the central region has a starting edge area and an ending edge area in the weft direction of the multi-layer woven fabric, wherein the central region comprises:
• a first woven layer having an upper and lower surfaces and comprising a plurality of first warp yarns and first weft yarns, wherein the upper surface of the first woven layer forms the first side of the multi-layer woven fabric;
• a second woven layer having an upper and lower surfaces and comprising a plurality of second warp yarns and second weft yarns, wherein the lower surface of the second woven layer forms the second side of the multi-layer woven fabric;
• and,
• a plurality of connecting yarns, wherein the connecting yarns connect the first woven layer and the second woven layer, wherein each connecting yarn has a stitching pattern that contains a first weave section, a crossover section, and a second weave section;
• and,
• an air impermeable layer located on the first side and the second side of the multi-layer woven fabric;
• wherein within the first weave section each connecting yarn is interwoven only with the first warp yarns of the first woven layer and the first weave section begins at the starting edge area of the central region and ends at a final weave stitch with the first warp yarns of the first woven layer;
• wherein within the crossover section each connecting yarn is not interwoven with any yarns of the multi-layer woven fabric, wherein the crossover section begins at the final weave stitch with the first warp yarns of the first woven layer and ends with a first weave stitch with the second warp yarns of the second woven layer, wherein the length of connecting yarn between the final weave stitch with the first warp yarns and the first weave stitch with the second warp yarns of the second woven layer is defined as the crossover distance;
• wherein within the second weave section each connecting yarn is interwoven only with the second warp yarns of the second woven layer and the second weave section begins at the first weave stitch with the second warp yarns of the second woven layer and ends at the ending edge area of the central region;
• and
• wherein within the starting edge area of the central region essentially all of the connecting yarns are not interwoven with the second woven layer and at least a portion of the connecting yarns are interwoven with the first woven layer, and wherein within the ending edge area of the central region essentially all of the connecting yarns are not interwoven with the first woven layer and at least a portion of the connecting yarns are interwoven with the second woven layer,
• wherein the air impermeable multi-layer woven fabric is configured to form a three-dimensional enclosed space having an outer surface and an inner surface;
• and,
• a port through the air impermeable multi-layer woven fabric.