3D fabric and preparing thereof

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.

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.

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.

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.

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.

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.

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.