THREE DIMENSIONAL FABRICS

• US 20140170389A1
• Filed: 12/18/2013
• Published: 06/19/2014
• Est. Priority Date: 12/19/2012
• Status: Abandoned Application

• Current Assignee: Laura Schwab, Matthew Schwab, Richard Schwab
• Original Assignee: Richard Schwab
• Inventors: SCHWAB, Matthew, SCHWAB, Laura, SCHWAB, Richard
• Application Number:
  US14/132,723
• Publication Number:
  US 20140170389A1
• Time in Patent Office: Days
• US Class Current: 428/160
• CPC Class Codes: A41D 31/145 using layered materials
• CPC Class Codes: Y10T 428/24512 Polyurethane

Abstract

Materials and methods for 3D fabrics are disclosed. The 3D fabrics have multiple layers including an outer layer of traditional fabric and a dimensional layer integrated with outer layer. The 3D fabrics have variable depth, typically ranging from between about 0.25 inches to about 2.0 inches. The 3D fabrics are produced from a molding process that creates the dimensional layer while adhering it to the outer layer. The 3D fabrics have unique visual properties which make them desirable for a variety of applications.

Claims

1. A three-dimensional fabric comprising:

a. a traditional fabric outer layer; and

b. a dimensional layer formed of polymer foam, said dimensional layer having a variable thickness.

2. The fabric of claim 1, where the dimensional layer has a variable thickness between about 0.25 and 4.0 inches.

3. The fabric of claim 1, where the dimensional layer has a variable thickness between about 0.25 and 2.0 inches.

4. The fabric of claim 1, where the polymer foam is an open cell foam.

5. The fabric of claim 1, where the polymer foam is a breathable open cell foam.

6. The fabric of claim 1, where the polymer foam is a polyurethane foam.

7. The fabric of claim 6, where the density of the foam is between about 2.0 and 4.0 pounds per cubic feet.

8. The fabric of claim 1, further comprising an inner traditional fabric layer.

9. The fabric of claim 1, where the outer layer is plain-colored.

10. The fabric of claim 1, where the outer layer has a pattern.

11. The fabric of claim 10, where the pattern has graphical depth.

12. The fabric of claim 11, where the physical depth of the dimensional layer matches the graphical depth of the pattern.

13. The fabric of claim 1, further comprising a raised feature.

14. A 3D fabric comprising:

a. a traditional fabric outer layer; and

b. a dimensional layer formed of polymer foam integrally bonded with the outer later, said dimensional layer having a variable thickness,

c. where the 3D fabric has flat areas without a dimensional layer, vein segments having a dimensional layer, and spacer segments without a dimensional layer between the vein segments.

15. The fabric of claim 14, where the dimensional layer has a variable thickness between about 0.25 and 4.0 inches.

16. The fabric of claim 14, where the dimensional layer has a variable thickness between about 0.25 and 2.0 inches.

17. The fabric of claim 14, where the density of the foam is between about 1 and 4 pounds per cubic feet.

18. The fabric of claim 14, where the density of the foam is between about 2.5 and 3.5 pounds per cubic feet.

19. The fabric of claim 14, where the stiffness of the vein segments is between about 0.5 and 4 times the value calculated from example 1.

20. The fabric of claim 14, where the stiffness of the vein segments is between about 0.5 and 2 times the value calculated from example 1.

21. The fabric of claim 14, where the vein segments are between about 1 and 8 inches in length.

22. The fabric of claim 14, where the vein segments are between about 2 and 5 inches in length.

23. The fabric of claim 14, where the spacer segments are between about 0.5 and 2 inches in length.

24. The fabric of claim 14, where the spacer segments are between about 0.5 and 1 inch in length.

25. The fabric of claim 14, where the outer layer is plain-colored.

26. The fabric of claim 15, where the outer layer has a pattern.

27. The fabric of claim 26, where the pattern has graphical depth.

28. The fabric of claim 27, where the physical depth of the dimensional layer matches the graphical depth of the pattern.

29. The fabric of claim 14, further comprising hub segments.

30. The fabric of claim 14, where the outer side of the traditional fabric layer is at least as soft to the touch as 220 grams per square inch Amerisuede (universal name is 3-bar) having a brushed polyester outer layer.

31. A 3D fabric comprising:

a. a traditional fabric outer layer; and

b. a dimensional layer formed of polymer foam, said dimensional layer having a consistent thickness between 1.0 and 3.0 cm thickness.