Three dimensional single-layer fabric and assembly methods therefor

• US 10,399,308 B2
• Filed: 12/05/2018
• Issued: 09/03/2019
• Est. Priority Date: 12/19/2012
• Status: Active Grant

• Current Assignee: Matthew J. Schwab
• Original Assignee: Matthew J. Schwab
• Inventors: Schwab, Matthew J.
• Primary Examiner(s): Dodds, Scott W
• Application Number:
  US16/210,654
• Publication Number:
  US 20190105882A1
• Time in Patent Office: 272 Days
• Field of Search: 156217
• CPC Class Codes: A41D 31/02 Layered materials characterised by special function or use A41D31/04
• CPC Class Codes: B29C 44/1219 Foaming between a movable mould part and the preformed part
• CPC Class Codes: B29C 44/3403 Foaming under special conditions, e.g. in sub-atmospheric pressure, in or on a liquid
• CPC Class Codes: B29C 51/10 Forming by pressure difference, e.g. vacuum
• CPC Class Codes: B29C 51/145 having at least one layer of textile or fibrous material combined with at least one plastics layer
• CPC Class Codes: B29C 65/02 by heating, with or without pressure
• CPC Class Codes: B29C 65/04 Dielectric heating, e.g. high-frequency welding , i.e. radio frequency welding of plastic materials having dielectric properties, e.g. PVC
• CPC Class Codes: B29C 65/06 using friction, e.g. spin welding non-plastics elements to plastic elements B29C65/645
• CPC Class Codes: B29C 65/08 using ultrasonic vibrations non-plastics element to plastics elements B29C65/645
• CPC Class Codes: B29C 65/16 Laser beams
• CPC Class Codes: B29C 65/48 using adhesives , i.e. using supplementary joining material; solvent bonding
• CPC Class Codes: B29C 65/50 using adhesive tape , e.g. thermoplastic tape; using threads or the like B29C65/3444 takes precedence
• CPC Class Codes: B29C 66/1122 Single lap to lap joints, i.e. overlap joints B29C66/45, B29C66/472, B29C66/52272 take precedence
• CPC Class Codes: B29C 66/431 Joining the articles to themselves B29C66/4322 and B29C66/4332 take precedence
• CPC Class Codes: B29C 66/861 Hand-held tools
• CPC Class Codes: B29C 66/863 Robotised, e.g. mounted on a robot arm
• CPC Class Codes: B29K 2075/00 Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2105/04 cellular or porous
• CPC Class Codes: B29K 2105/253 Preform
• CPC Class Codes: B29L 2031/48 Wearing apparel
• CPC Class Codes: B29L 2031/726 : Fabrics nets B29L2028/00
• CPC Class Codes: B32B 2262/0276 : Polyester fibres
• CPC Class Codes: B32B 2262/062 : Cellulose fibres, e.g. cotton
• CPC Class Codes: B32B 2262/14 : Mixture of at least two fibres made of different materials
• CPC Class Codes: B32B 2266/0278 : Polyurethane
• CPC Class Codes: B32B 2266/06 : Open cell foam
• CPC Class Codes: B32B 2307/4026 : within the layer by addition of a colorant, e.g. pigments, dyes
• CPC Class Codes: B32B 2307/546 : Flexural strength; Flexion stiffness
• CPC Class Codes: B32B 2307/72 : Density
• CPC Class Codes: B32B 2307/724 : Permeability to gases, adsorption
• CPC Class Codes: B32B 2307/732 : Dimensional properties
• CPC Class Codes: B32B 2437/00 : Clothing
• CPC Class Codes: B32B 2607/02 : Wall papers, wall coverings
• CPC Class Codes: B32B 27/065 : of foam
• CPC Class Codes: B32B 27/12 : next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/36 : comprising polyesters
• CPC Class Codes: B32B 27/40 : comprising polyurethanes
• CPC Class Codes: B32B 3/10 : characterised by a discontinuous layer, i.e. formed of separate pieces of material
• CPC Class Codes: B32B 5/024 : Woven fabric
• CPC Class Codes: B32B 5/026 : Knitted fabric
• CPC Class Codes: B32B 5/06 : characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
• CPC Class Codes: B32B 5/08 : the fibres or filaments of a layer being of different substances , e.g. conjugate fibres, mixture of different fibres
• CPC Class Codes: B32B 5/18 : characterised by features of a layer of foamed material
• CPC Class Codes: B32B 5/26 : another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: B32B 7/05 : the layers not being connected over the whole surface, e.g. discontinuous connection or patterned connection using interposed adhesives or bonding materials applied in spaced arrangements B32B7/14
• CPC Class Codes: B32B 7/12 : using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: Y10T 428/24512 : Polyurethane

Abstract

A single-layer 3D fabric of traditional camouflage synthetic fabric with outwardly extending random hollow tunnels therein with weldments in the fabric layer intermittently along the tunnels to hold the outwardly extending hollow tunnels in place. The tunnels have variable depth, typically ranging from between about 0.25 inches to about 2.0 inches. The 3D fabric is produced from a molding process that creates the outer dimensional layer. The 3D fabrics have unique visual properties which make them desirable for a variety of applications.

Claims

1. A method of making a three-dimensional single-layer fabric from a flat master mold forming plate with a top side having upstanding random curved blades or pins of different heights with gaps along the length of the random curved blades or pins, comprising:

a) placing a synthetic fabric over the master mold forming plate;

b) moving the fabric down onto the plate and over the blades or pins forming random curved tunnels of different heights with bases;

c) intermittently hand bonding the tunnels at their bases in the gaps making tall and short tunnels thereby making the three-dimensional single-layer fabric; and

d) removing the three-dimensional single-layer fabric from the master mold forming plate.

2. The method of claim 1, where the bonds are chosen from a group consisting of sonic welds, heat welds, vibration welds, laser welds, RF welds and adhesive bonds.

3. The method of claim 1, wherein the gaps are approximately 3.5 inches long.

4. The method of claim 1, wherein the tunnels are between 1 and 60 inches in length.

5. The method of claim 1, wherein the tunnels have a variable height between 0.25 and 4.0 inches.

6. A method of making a three-dimensional single-layer fabric from a flat master mold forming plate with a top side having upstanding random curved blades or pins of different heights with gaps along the length of the random curved blades or pins, comprising:

a) placing a synthetic fabric against the master mold forming plate;

b) moving the fabric down onto the plate and over the blades or pins forming random tunnels between 1 and 60 inches in length and between 0.25 and 4.0 inches in variable height;

c) intermittently hand bonding the tunnels at their bases in the gaps approximately 3.5 inches apart thereby making the three-dimensional single-layer fabric; and

d) removing the three-dimensional fabric from the master mold forming plate.

7. The method of claim 6, where the bonds are chosen from a group consisting of sonic welds, heat welds, vibration welds, laser welds, RF welds and adhesive bonds.