Three-dimensional fabric and method of producing the same

A three-dimensional fabric comprising:

• first and second fabric pieces each including at least two substantially flat plate sections arranged in intersecting planes, wherein the intersection of adjacent plate sections define a right angle bend;
• the first and second fabric pieces each have a plurality of thread layers that extend continuously through and between the adjacent sections, the portions of the thread layers within each plate section extending in planes that are perpendicular to a transverse direction that passes through the corresponding plate section, the plurality of thread layers including threads that are woven in at least two independent directions;
• and
• at least one transverse thread woven through the thread layers in the transverse direction of the corresponding plate sections to couple the thread layers together.

A method of producing a three-dimensional fabric having a plurality of plate sections connected into a T-shape joint, utilizing first and second frame members having L-shaped active portions and a third frame member having a substantially flat active portion the method comprising the steps of:

• providing each frame member with a matrix of removable regulating members that extend perpendicularly to their respective active surfaces;
• weaving threads between the regulating members of each frame member in at least two independent directions to form a thread layer, above the active surface of the corresponding frame, the L-shaped members being woven such that their thread layer extends continuously through a bend formed in the L-shaped member;
• removing the thread layers together with the regulating members from their respective frames;
• weaving transverse threads through the bend portions of the thread layers and portions of the flat fabric piece that are adjacent the bend portions, by replacing the associated regulating members with the transverse thread to couple the threads of the associated thread layer portion together;
• arranging the woven thread layers in a substantially T-shaped relationship wherein each leg of the T has a pair of adjacent woven thread layers;
• and
• sequentially weaving transverse threads through adjacent woven thread layers by replacing adjacent regulating members of the adjacent thread layers with the transverse thread to couple the thread layers.