U.S. patent application number 15/254112 was filed with the patent office on 2016-12-22 for three dimensional single-layer fabric and assembly methods therefor.
The applicant listed for this patent is Matthew J. SCHWAB. Invention is credited to Matthew J. SCHWAB.
Application Number | 20160368249 15/254112 |
Document ID | / |
Family ID | 57587373 |
Filed Date | 2016-12-22 |
United States Patent
Application |
20160368249 |
Kind Code |
A1 |
SCHWAB; Matthew J. |
December 22, 2016 |
THREE DIMENSIONAL SINGLE-LAYER FABRIC AND ASSEMBLY METHODS
THEREFOR
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.
Inventors: |
SCHWAB; Matthew J.; (Eau
Claire, WI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SCHWAB; Matthew J. |
Eau Claire |
WI |
US |
|
|
Family ID: |
57587373 |
Appl. No.: |
15/254112 |
Filed: |
September 1, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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15211211 |
Jul 15, 2016 |
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15254112 |
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14956979 |
Dec 2, 2015 |
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15211211 |
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14132723 |
Dec 18, 2013 |
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14956979 |
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61797962 |
Dec 19, 2012 |
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61852146 |
Mar 15, 2013 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B29C 65/08 20130101;
B32B 5/08 20130101; B29C 65/48 20130101; B32B 2266/0278 20130101;
B29C 44/3403 20130101; B32B 2307/4026 20130101; B32B 2607/02
20130101; B32B 27/12 20130101; B29C 66/1122 20130101; B29K 2105/253
20130101; B32B 7/12 20130101; B32B 2437/00 20130101; B29C 44/1219
20130101; B29C 65/06 20130101; B32B 27/36 20130101; B32B 2262/14
20130101; Y10T 428/24512 20150115; B29K 2105/04 20130101; B32B 5/26
20130101; B29C 65/04 20130101; B29C 66/431 20130101; B32B 5/18
20130101; B32B 27/40 20130101; B29C 65/50 20130101; B32B 2262/062
20130101; B32B 7/05 20190101; B32B 2266/06 20130101; B29C 65/02
20130101; B32B 5/026 20130101; B29C 66/861 20130101; B29C 51/10
20130101; B32B 27/065 20130101; B32B 2307/724 20130101; B29C 66/863
20130101; B32B 2307/546 20130101; B32B 2262/0276 20130101; A41D
31/02 20130101; B29C 65/16 20130101; B29L 2031/48 20130101; B32B
2307/72 20130101; B29C 51/145 20130101; B29L 2031/726 20130101;
B29K 2075/00 20130101; B32B 5/024 20130101; B32B 2307/732 20130101;
B32B 5/06 20130101; B32B 3/10 20130101 |
International
Class: |
B32B 27/12 20060101
B32B027/12; B29C 44/34 20060101 B29C044/34; B29C 65/08 20060101
B29C065/08; B29C 65/04 20060101 B29C065/04; B32B 5/18 20060101
B32B005/18; B29C 65/50 20060101 B29C065/50; B32B 27/40 20060101
B32B027/40; B32B 5/02 20060101 B32B005/02; B32B 27/36 20060101
B32B027/36; B32B 27/06 20060101 B32B027/06; B29C 44/12 20060101
B29C044/12; B29C 65/16 20060101 B29C065/16 |
Claims
1. A single-layer three-dimensional fabric comprising: a. a
synthetic fabric layer with outwardly extending random hollow
tunnels therein; and b. weldments in the fabric layer
intermittently along bases of the tunnels to hold the outwardly
extending hollow tunnels in place.
2. The three-dimensional fabric of claim 1, where the tunnels have
a variable height between about 0.25 and 4.0 inches.
3. The three-dimensional fabric of claim 1, where the outer layer
is plain-colored.
4. The three-dimensional fabric of claim 1, where the outer layer
has a pattern.
5. The three-dimensional fabric of claim 4, where the pattern has a
graphical depth.
6. The three-dimensional fabric of claim 5, where the outwardly
extending tunnels match the graphical depth of the pattern. 7, The
three-dimensional fabric of claim 1 wherein the weldments are
formed by one of the following sonic welds, heat welds, vibration
welds, laser welds, RF welds, adhesive or bonding approximately 3.5
inches apart.
8. The three-dimensional fabric of claim 1, where the tunnels are
curved and between about 1 and 60 inches in length.
9. The three-dimensional fabric of claim 1, wherein the
three-dimensional fabric is for making camouflage clothing and
hunting blinds.
10. A three-dimensional fabric comprising: a. a synthetic fabric
layer with outwardly extending random curved hollow tunnels therein
each with a base, wherein the tunnels have a variable height
between about 0.25 and 4.0 inches and wherein the tunnels are
between about 1 and 60 inches in length b. weldments in the fabric
layer intermittently along bases of the tunnels to hold the
outwardly extending hollow tunnels in place, wherein the
three-dimensional fabric has flat areas and raised tunnel
segments.
11. The three-dimensional fabric of claim 10, where the outer layer
is plain-colored.
12. The three-dimensional fabric of claim 10, where the outer layer
has a pattern.
13. The three-dimensional fabric of claim 12 where the pattern has
graphical depth.
14. The three-dimensional fabric of claim 13, where the raised
tunnel segments of the outer layer match the graphical depth of the
pattern.
15. The three-dimensional fabric of claim 10, wherein the
three-dimensional fabric is for making camouflage clothing and
hunting blinds.
16. A method of making a three-dimensional single-layer fabric,
comprising: a) placing a synthetic fabric over a master mold
forming plate with upstanding random curved blades with gaps
therebetween and vacuum ports in the plate adjacent the blades; b)
moving the fabric down onto the plate and over the blades or pins
forming random curved tunnels with bases; c) applying vacuum
through the ports to draw the fabric down onto the plate; c)
intermittently bonding the tunnels at their bases in the gaps
making the three-dimensional tunneled fabric; d) removing the
finished three-dimensional fabric from the master mold forming
plate.
17. The method of claim 16, where the bonds are chosen from a group
comprising sonic welds, heat welds, vibration welds, laser welds,
RF welds and adhesion and the bonds are approximately 3.5 inches
apart.
18. The three-dimensional fabric of claim 16, wherein the gaps are
approximately 3.5 inches long.
19. A method of making a three-dimensional single-layer fabric,
comprising: a) placing a synthetic fabric against a master mold
forming plate with channels therein; b) moving a push plate
upstanding random curved blades with gaps therebetween as to insert
the fabric and the blades into the channels forming tunnels in the
fabric; c) intermittently bonding the tunnels at their bases in the
gaps making the three-dimensional tunneled fabric; d) removing the
finished three-dimensional fabric from the master mold forming
plate.
Description
PRIORITY CLAIM
[0001] This Continuation-In-Part application claims priority to
Utility patent application Ser. No. 15/211,211, filed Jul. 15,
2016, which claims priority to Utility patent application Ser. No.
14/956,979, filed Dec. 2, 2015 which claims priority to Utility
patent application Ser. No. 14/132,723, filed Dec. 18, 2013 which
claims priority to U.S. Provisional Patent Application No.
61/797,962, filed Dec. 19, 2012, and U.S. Provisional Patent
Application No. 61/852,146, filed Mar. 15, 2013, the contents of
which are both incorporated by reference herein.
FIELD OF THE INVENTION
[0002] The present invention relates to three-dimensional ("3D")
fabrics.
BACKGROUND OF THE INVENTION
[0003] Camouflage suits for bow-hunting deer typically are made
with fabrics having printed patterns intended to blend in with
colors and patterns in the hunter's background. More elaborate
camouflage suits, such as the ghillie suit, are also available.
There is a need for improved camouflage suits that blend into the
background. The materials and methods developed for camouflage
suits have broad applicability in other areas as well.
BRIEF DESCRIPTION OF THE INVENTION
[0004] 3D fabrics maybe a single layer or have multiple layers
including an outer dimensional layer of traditional fabric and a
liner layer integrated with outer layer suitable with air or foam
therebetween. The 3D fabrics have variable depth, typically ranging
from between about 0.25 inches to about 4.0 inches. The 3D fabrics
are produced from a master mold and process that creates the outer
dimensional layer while not adhering the outer layer to a liner
layer. The 3D fabrics have unique visual properties which make them
desirable for a variety of applications.
[0005] A principal object and advantage of the 3D fabrics of the
invention are that they are easily sewable using conventional
equipment, as the dimensional outer layer is compressible during
the sewing process. However, in some applications where thick
dimensional layers are desired in portions of the fabric, it may be
desirable to design and manufacture the fabric to have thinner
areas of the dimensional layer in accordance with specific
patterns. In some cases, the 3D fabric may include areas without
the dimensional layer for application-specific needs.
[0006] Another principal object and advantage of the 3D fabrics of
the invention is that they have a wide variety of applications.
They may be used for camouflage hunting apparel. They may be used
for military camouflage apparel. They may be used for producing
ordinary apparel (such as coats, pants, hats, shoes, etc.) with
interesting visual effects. They may be used for producing ordinary
apparel for their insulating properties. They may be used for
furniture coverings. They may be used in wall coverings. They may
be used in set designs. Specialty outer and inner fabric layers may
be incorporated for properties such as sonic insulation, thermal
insulation, heat retention, heat reflectivity, indetectability to
remote sensors (radar, sonar, infra-red detectors, and the like).
Electronics may be molded into the dimensional layer for purposes
of communication, monitoring of body functions, lighting and the
like). Other applications of the fabrics will also become apparent
over time.
[0007] Another principal object and advantage of the 3D fabrics of
the invention he present invention is that the fabrics include
materials and methods to produce unique wearable three-dimensional
(3-D) fabrics 5. The fabrics 5 comprise an optional inner fabric
layer 12, a dimensional layer 10 made of breathable foam, and a
patterned outer layer 8. The dimensional layer 10 may be molded to
have contours matching the pattern of the outer layer 8, with the
resulting multilayer fabric 5 or 26 having both physical and
graphical depth.
[0008] Another principal object and advantage of the 3D fabrics of
the invention is that one application of this technology is to
create camouflaged clothing articles. For example, a suit
comprising a jacket and pants may have a tree or woods motif, where
the dimensional layer is specifically contoured to match
graphically patterned branches and leaves on the outer fabric
layer. Preferably, the depth of the 3D fabric varies from about
0.25 inches to about 4.0 inches, and more preferably from about
0.25 inches to about 2.0 inches. Outer fabric layer patterns may
include trees, leaves, branches, grassland vegetation, and the
like. The patterns may be selected from different types of outdoor
environments: oak woods, pine forests, maple forests, and the
like.
[0009] Another principal object and advantage of the 3D fabrics of
the invention is that the 3D fabrics used to make the articles of
clothing are constructed out of pattern panels (e.g., sleeves,
collar, back, etc. . . ) that are formed in molded sections. Each
section includes all the pattern panels for the given article of
clothing. The pattern panels will be arranged on the molded
sections to minimize waste. Clothing articles made of 3D fabrics
include normal clothing features such as pockets and zippers.
[0010] Another principal object and advantage of the 3D fabrics of
the invention is that the printed or graphical patterns on the
outer fabric layer are selected or designed to match the physical
depth of the 3D fabric, i.e., a printed branch on the pattern will
correspond with the shape of the branch on the 3D fabric. This is
useful for camouflage and other applications. However, it is within
the scope of the invention to have 3D physical patterns that do not
match the graphical patterns.
[0011] Another principal object and advantage of the 3D fabrics of
the invention is that the fabric liner may be a sheet of material,
a strip or fabric welding tape which makes the 3D fabrics
relatively inexpensive and easy to manufacture at one master mold
station.
[0012] Another principal object and advantage of the single-layer
3D fabric of the invention is that the fabric need not a liner
which makes the 3D fabric relatively inexpensive and easy to
manufacture at one master mold station.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The accompanying drawings, which are incorporated into and
constitute a part of this specification, illustrate one or more
embodiments of the present invention and, together with the
detailed description, serve to explain the principles and
implementations of the invention.
[0014] In the drawings:
[0015] FIG. 1 depicts a cross-sectional view of a first embodiment
of a 3D fabric.
[0016] FIG. 2 depicts a cross-sectional view of an embodiment of a
mold for making the first embodiment of the 3D fabric.
[0017] FIG. 3 depicts an embodiment of a method of making the 3D
fabric.
[0018] FIG. 4A-4C depicts a testing method for compatibility of
fabrics with foam mixtures and reaction conditions.
[0019] FIG. 5 depicts an embodiment of a mold for making the 3D
fabric in a continuous process.
[0020] FIG. 6 depicts another cross-sectional view of a first
embodiment of a 3D fabric.
[0021] FIG. 7 depicts a cross-sectional view of a second embodiment
of a 3D fabric.
[0022] FIG. 8 depicts a cross-sectional view of an embodiment of a
mold for making the second embodiment of the 3D fabric.
[0023] FIG. 9A depicts a top plan view of a third embodiment of a
3D fabric.
[0024] FIG. 9B depicts a cross section taken along lines 9B-9B of
FIG. 9A and FIG. 10.
[0025] FIG. 10 depicts a bottom plan new of the third embodiment of
the 3D fabric layer and the dimensional layer.
[0026] FIG. 11 depicts a cross section taken along lines 11-11 of
FIG. 10.
[0027] FIG. 12 depicts an enlarged bottom plan view of the outer
fabric layer and the dimensional layer of the third embodiment of
the 3D fabric.
[0028] FIG. 13A depicts a top plan view of the bottom mold
portion.
[0029] FIG. 13B depicts a side view of the bottom mold portion.
[0030] FIG. 14A depicts a top plan view of the bottom mold portion
with the outer fabric in place.
[0031] FIG. 14B depicts a side view of the bottom mold potion with
the outer fabric in place.
[0032] FIG. 15 depicts a top plan view of the bottom mold portion
with the dimensional layer in place with fabric holders.
[0033] FIG. 16 depicts a top plan view of the bottom mold portion
with the fabric holders removed.
[0034] FIG. 17 depicts a top plan view of the bottom mold portion
with new fabric holders in place.
[0035] FIGS. 18A-18E depict a variety of fabric holders.
[0036] FIG. 19 depicts a process for manufacturing the 3D
fabric.
[0037] FIG. 20 depicts a master mold for manufacturing a fourth
embodiment of a 3D fabric.
[0038] FIG. 21 depicts a cross sectional view through lines 21-21
of the mold of FIG. 20.
[0039] FIG. 22 depicts a bottom plan view of a top mold section
that nests into the master mold of FIGS. 20 and 21.
[0040] FIG. 23 depicts a top plan view of the top mold section of
FIG. 22.
[0041] FIG. 24 depicts a top plan view of the master mold for
manufacturing the fourth embodiment of a 3D fabric with the
exterior fabric in position on the master mold and a section of the
top mold in position on the master mold at the first station.
[0042] FIG. 25 depicts a cross sectional view of the master mold,
outer fabric and top mold along lines 25-25 of FIG. 24.
[0043] FIG. 26 depicts a cross sectional view of the master mold,
outer fabric, inner fabric of FIG. 24 with the sonic welder
positioned thereabove.
[0044] FIG. 27 depicts a side elevational view of the first station
in the assembly method of making the 3D fabric.
[0045] FIG. 28 depicts a side elevational view of the second
station in the assembly method of making the 3D fabric.
[0046] FIG. 29 depicts a cross sectional view through the finished
3D fabric through lines 29-29 of FIG. 30.
[0047] FIG. 30 depicts a top plan view of the finished 3D
fabric.
[0048] FIG. 31 is a perspective top plan view of the partially
finished fifth embodiment of a 3D fabric partially rolled back on
the master mold.
[0049] FIG. 32 depicts a side elevational view of the first step in
the assembly method of making the 3D fabric of the fifth
embodiment.
[0050] FIG. 33 depicts a cross sectional view of the master mold
and second step assembly method of making the 3D fabric of the
fifth embodiment.
[0051] FIG. 34 is a perspective bottom plan view of the finished
fifth embodiment of a 3D fabric partially rolled back.
[0052] FIG. 35 is a top plan view of the master mold forming plate
for the first making a six embodiment of the 3D single-layer
synthetic fabric (FIG. 43) of the present invention.
[0053] FIG. 36 a cross sectional view taken along lines 36-36 of
FIG. 35.
[0054] FIG. 37 is an end view of the single-layer 3D fabric master
mold forming plate for the making of the 3D fabric of the sixth
embodiment.
[0055] FIG. 38 is a cross sectional view taken along lines 38-386
of FIG. 35.
[0056] FIG. 39 is a top plan view of the master mold forming plate
for a second method of making the six embodiment of the 3D
single-layer synthetic fabric (FIG. 43) of the present
invention.
[0057] FIG. 40 a cross sectional view taken along lines 40-40 of
FIG. 39.
[0058] FIG. 41 is a top plan view of the push plates that next into
the underside of the master mold forming plate for the second
making a six embodiment of the 3D single-layer synthetic fabric
(FIG. 43) of the present invention.
[0059] FIG. 42 is an end view of the assembly of the push plates
that next into the underside of the master mold forming plate for
the second method of making a six embodiment of the 3D single-layer
synthetic fabric (FIG. 43) of the present invention.
[0060] FIG. 43 is a side perspective view partially broken away of
the six embodiment of the 3D single-layer synthetic fabric of the
present invention.
DETAILED DESCRIPTION
[0061] Embodiments of the present invention are described herein in
the context of compositions of three dimensional (3D) fabrics and
methods for making 3D fabrics and articles using 3D fabrics. Those
of ordinary skill in the art will realize that the following
detailed description of the present invention is illustrative only
and is not intended to be in any way limiting. Other embodiments of
the present invention will readily suggest themselves to such
skilled persons having the benefit of this disclosure. Reference
will now be made in detail to implementations of the present
invention as illustrated in the accompanying drawings. The same
reference indicators will be used throughout the drawings and the
following detailed description to refer to the same or like
parts.
[0062] In the interest of clarity, not all of the routine features
of the implementations described herein are shown and described. It
will, of course, be appreciated that in the development of any such
actual implementation, numerous implementation-specific decisions
must be made in order to achieve the developer's specific goals,
such as compliance with application and business-related
constraints, and that these specific goals will vary from one
implementation to another and from one developer to another.
Moreover, it will be appreciated that such a development effort
might be complex and time-consuming, but would nevertheless be a
routine undertaking of engineering for those of ordinary skill in
the art having the benefit of this disclosure.
Definitions
[0063] "Traditional fabrics" are essentially flat, single layer
materials such as cotton cloth, wool cloth, synthetic or synthetic
blend cloth, and felt. While these fabrics have a dimension of
thickness or depth, the thickness is typically small (less than
about 3 mm) and uniform.
[0064] "Three dimensional fabric" or "3D fabric" refers to a
multilayer fabric having an outer dimensional fabric layer and a
liner layer that gives the fabric variable physical depth, where
the outer layer is integrally bonded to the liner layer be it a
sheet, strips or tape. In some cases, the liner layer maybe the
dimensional layer.
[0065] FIGS. 1 through 6 depicts a cross-sectional view of a first
embodiment 5 of a 3D fabric and method of making. In the figure, 3D
fabric 5 comprises outer fabric layer 8 and dimensional layer 10.
Outer fabric layer 8 is a traditional fabric and has a consistent
thickness that makes up only a small fraction of the overall
thickness of the 3D fabric 5. Dimensional layer 10 provides
variable physical depth to the fabric. In this first embodiment,
the dimensional layer has a variable thickness, with one
essentially flat side and a contoured side. The minimum
thickness/depth of this first embodiment of 3D fabric 5 is shown by
dimension A and the maximum thickness/depth of 3D fabric 5 is shown
by dimension B. Because of the flat side, the thickness of the
dimensional layer is about the same as the depth of the 3D fabric.
3D fabric may also optionally include inner fabric layer 12.
[0066] FIG. 6 also depicts a cross-sectional view of a slight
variation of the first embodiment 5, showing an additional feature.
Raised feature 14 is a part of the 3D fabric 5 where dimensional
layer 10a is significantly thicker (F plus H) than the adjoining
dimensional layer 10b (thickness H). Raised features may be defined
as having an extra thickness F that is about equal to or greater to
the width G of the feature and/or having a double-back area 16
where outer fabric layer 8 doubles back across itself when viewed
in cross-section. Raised features may be used for a variety of
purposes. They may be used to give the appearances of sticks or
branches in camouflage 3D fabrics 5. They may be used to simulate
objects in other applications (e.g., a cartoon character head on a
jacket or necktie). They may also simply be used to simply provide
visual interest. Because of physical limitations, they require that
the thickness of the dimensional layer 10 is not uniform, though
raised features may be incorporated into the embodiment of 3D
fabrics shown in FIG. 7 with uniform thickness.
[0067] FIG. 2 depicts a cross-sectional view of an embodiment of a
compression mold 20 for making the first embodiment of the 3D
fabric 5. In this embodiment, the mold comprises a dimensional
portion 22 and a flat portion 24.
[0068] FIG. 7 depicts a cross-sectional view of a second embodiment
of a 3D fabric 26. In the figure, 3D fabric 26 comprises outer
fabric layer 28 and dimensional layer 30. As in the first
embodiment, outer fabric layer 28 has a consistent thickness that
makes up only a small fraction of the overall thickness of the 3D
fabric 26. In this second embodiment 26, the dimensional layer 30
has a more uniform thickness C, with contours on both sides. In
this second embodiment 26, the thickness C of the dimensional layer
30 is not the same as the depth D of the 3D fabric 26. The
thickness of the fabric 26 is essentially uniform, while the depth
D is variable, thereby providing the physical 3D effect. 3D fabric
26 may also optionally include inner fabric layer 32. In this
embodiment, the dimensional layer 30 is preferably between about
0.5 to 10.0 cm thick, and more preferably between about 1.0 and 3.0
cm thick.
[0069] FIG. 8 depicts a cross-sectional view of an embodiment of a
compression mold 36 for making the second embodiment of 26 the 3D
fabric. Both parts of the mold are contoured, and may be referred
to as lower portion 38 and upper portion 40. During the molding
process, the molds are 38 and 40 positioned to be separated by the
thickness of the dimensional layer 30.
[0070] It is within the invention to produce molds and fabrics
intermediate and in combination between those embodiments depicted
in FIGS. 1, 2 and 6 and those depicted in FIGS. 7 and 8 by having
the upper mold portion 24 not be completely flat, yet not designed
to have a uniform molding distance from the lower mold. The
resulting fabrics will have two contoured sides without having a
uniform thickness. In such cases, the portions of the fabric having
the most depth will generally also have the greatest thickness.
[0071] In both embodiments, the outer fabric layer 8 or 28 is
preferably colored or patterned on the outer surface side. The
optional inner fabric layer 12 or 32 is typically not visible when
the 3D fabric 5 or 26 is incorporated into an article of
clothing.
[0072] The dimensional layer 10 or 30 comprises a flexible,
open-cell polyurethane foam with a preferred density between about
2.0 and 4.0 pounds/cubic foot, and more preferably a density
between about 2.8 and 3.4 pounds/cubic foot. The foam is formed by
a polymerization reaction between an isocyanate component and a
polyol component that are mixed immediately prior to molding.
Mixing the components produces a viscous dense liquid, which will
be referred to herein as the "foam mixture." As the polymerization
reaction progresses, gases are produced which form the cells in the
foam and results in an increase in volume of the mixture. The "rise
time" is the period of volume expansion. In the context of the
present invention, the two parts of the mold must be positioned
during the rise time, thereby confining the dimensional layer
before the end of the rise time.
[0073] The properties of the foam mixture dictate certain aspects
of the manufacturing process. FIG. 3 describes the steps in an
embodiment of a method for making the 3D fabric 5 or 26. Step 31
requires preparing an upper mold (e.g., portion 24 in FIG. 2 or
portion 40 in FIG. 8) and a lower mold, (e.g., portion 22 in FIG. 2
or portion 38 in FIG. 8). Step 33 requires placing an outer fabric
8 or 28 in the lower mold 22 or 38 with the outer surface of the
outer fabric facing downwards. Step 35 requires then applying foam
mixture on top of the outer fabric. Step 37 requires positioning
the upper mold 24 or 40 before the end of the rise time. Step 39
requires releasing the 3D fabric 5 or 26 from the mold. While this
relatively simple process is at the core of the technology, almost
unlimited variations are possible in the making of the 3D fabric 5
or 26, the 3D fabrics produced from the process, and the articles
that can be made using the 3D fabric.
[0074] Because of the density and viscosity of the foam mixture, it
is presently preferable that the foam mixture be applied to the top
of the outer fabric layer. This can be done manually, though mixing
of the components of the foam mixture and application of the foam
mixture over the outer fabric layer are preferably done by machine.
A variety of mixing heads are presently available to mix the
components. Specialty automated processes and robots may be
designed to apply the foam mixture in desired amounts at particular
points depending on the desired product. If the dimensional layer
is to be of uniform thickness as in FIG. 7, the foam mixture is
applied uniformly over the outer fabric layer. If the dimensional
layer is to be of variable thickness as in FIGS. 1 and 6, it may be
advantageous to apply the foam mixture proportionally according to
the thickness required by the distance between the upper and lower
molds (e.g., areas with raised features).
[0075] Though it is presently preferred to produce the 3D fabrics
by applying the foam mixture to the bottom of the outer fabric
layer, it is also possible to produce the fabrics by applying the
foam mixture to the top of an inner fabric layer and then apply the
outer fabric layer over the foam mixture, allowing the foam mixture
to rise to fit the contours of a contoured upper mold. Further, it
is possible to produce the 3D fabrics in an arrangement where the
inner and outer fabric layers are vertical and the foam mixture is
applied between them in a continuous process.
[0076] Manufacture of 3D fabrics may be done by producing
individual sheets having defined sizes using substantially planar
fixed molds as depicted in FIGS. 2 and 8. In a presently preferred
method, after the upper and lower molds are prepared, the outer
fabric layer is placed with its outer side down onto the lower
mold. Optionally, the outer fabric layer is fitted closely to the
lower mold by air jets, vacuum, or forcing the fabric into place
with a positioning plate that matches the contours of the lower
mold. (the positioning plate may be same piece as the upper mold).
Then the foam mixture is applied over the outer fabric layer,
either by hand or by automated processes employing metering pumps,
mix heads, robots, and/or computer controlled dispensing rates.
Optionally, an inner fabric layer is placed over the foam mixture.
Before the end of the rise time, the upper mold is applied at a
defined distance from the lower mold to confine the dimensional
layer. When the polymerization reaction is sufficiently complete,
the 3D fabric is released from the mold.
[0077] Manufacture of the 3D fabric 5 or 26 may also be performed
in a continuous process, as shown in FIG. 5. The continuous process
uses moving molds where one or both of the molds is contoured,
continuous feeds of outer layer fabric and inner layer fabric, and
continuous application of foam mixture. Because the polyurethane
polymerization process requires substantial time, the rate of the
continuous process is limited. However, the use of increased
temperatures and catalysts can speed the polymerization process so
that reasonable output is achievable. The continuous process
preferably uses a horizontal orientation as shown in FIG. 5, though
vertical and intermediate configurations are within the scope of
the invention.
[0078] Referring to FIG. 5 (not to scale), lower mold portion 71
comprises a continuously moving track. Lower mold portion 71 may be
made of flexible material or segmented metal. Outer fabric layer 8
is fed onto lower mold portion 71. Optional air jet 81 conforms
outer fabric 8 to the contours of lower mold portion 71. Foam
mixture 66 is applied onto the outer fabric layer 8 by foam mixture
applicator 73. Foam mixture applicator 73 may comprise a single
dispensing head that moves laterally across the lower fabric, or a
plurality of dispensing heads that may be fixed or movable. The
rise time of foam mixture 66 progresses as it is carried along by
lower mold portion 71. When the rise time has progressed
sufficiently, the foam mixture reaches the upper mold portion 72,
which may comprise one or more rotating drums 72. At that point,
dimensional layer 10 is confined by the molds as the rise
period/rise time completes. The speed of the lower mold portion 71
is designed so that polymerization is substantially complete by the
time the fabric 8 is past the upper mold portion 72. Temperature,
catalysts, foam mixture and track and drum rotation speeds are
calibrated to produce a 3D fabric 5 with the required properties as
described elsewhere in this specification. Finished 3D fabric 5
comes through the mold with the rise time complete and the
dimensional layer in its final form. Though FIG. 5 illustrates the
continuous process in the presently preferred embodiment of having
a dimensional mold portion 71 on the bottom and a flat mold portion
72 above, the arrangement of inner 12 and outer 8 fabrics as well
as the selection and arrangement of the mold portions may be varied
as described elsewhere in this specification. The incorporation of
optional inner fabric layer 12 may be included in the process.
[0079] It is essential to the invention that the outer fabric layer
8 and the dimensional layer 10 are integrally bonded to each other.
If an inner fabric layer 12 is present, the inner fabric layer 12
is also preferably integrally bonded with the dimensional layer 10.
In a presently preferred embodiment, such bonding is achieved by
the molding process. The outer fabric layer 8 is preferably
breathable and porous, allowing adhesion of the fabric layer and
foam mixture before the foam mixture sets. When the resin sets and
forms the dimensional layer, it also binds the dimensional layer 10
to the outer fabric layer 8. The dimensional layer 10 is preferably
an open-cell foam. Polyurethane at a density of about three pounds
per cubic foot is a preferable material for its lightness,
washability, breathability, and durability.
[0080] Bleeding and staining are two potential problems in the
manufacturing of the 3D fabrics of the invention. Bleeding results
in the foam mixture penetrating the outer layer before the
polymerization reaction is complete, and results in visible foam on
the outer surface of the fabric. Staining is less obvious than
bleeding, but results in discoloration of the outer fabric layer.
Several variables may affect these problems. The variables include:
1. type of fabric (cotton, polyester, blend, etc.); 2. Porosity of
fabric (woven vs. knit, tightness of weave or knit, thread count,
etc. . . ); 3. Fabric treatments (waterproofing, starch, etc. . .
); 4. type of foam mixture; 5. amount of foam mixture; 6. timing
and temperature during molding; 7. pressure on foam during molding;
and 8. use of catalysts or other chemical additives in the foam
mixture. As described in the examples, tests have been carried out
to determine the effects of these variables.
[0081] Based upon the test results described in the examples,
fabrics may be placed in one of several categories. "High porosity"
fabrics are those having significant bleed-through during the
molding process with no pressure exerted by an upper mold portion.
"Medium porosity" fabrics are those means having no significant
bleed-through with no pressure, but significant bleed-through under
low pressure. "Low porosity" fabrics are those having no
significant bleed-through during the molding process under low
pressure. "Impermeable" fabrics are those that have no significant
bleed-through under high pressure. Though high porosity and medium
porosity fabrics are useful for some applications of the invention,
for applications where the prevention of bleed-through is important
as well as breathability, the most preferred fabrics are low
porosity fabrics including: tightly-woven synthetic microfibers,
tightly-knit synthetic microfibers, tightly-woven natural
microfibers, tightly-knit natural microfibers, and tightly-woven
cotton/polyester blends with a thread count above 150. Such
preferences apply to both the inner fabric layer and the outer
fabric layer. Specifically preferred fabrics for the outer layer
include Amerisuede 2-bar 100% polyester with a warped knit and
brushed face and a weight of 220 grams per square meter, Amerisuede
3-bar 100% polyester with a warped knit and brushed face and a
weight of 280 grams per square meter and 100% polyester knit
fleece.
[0082] During the rise time, the pressure exerted by the mold
portions against the polyurethane is dependent upon a number of
factors. Though it is possible to control the mold portions to a
set pressure point, in practice it is preferable to rigidly fix the
distance between the mold portions. In such an arrangement, the
pressure exerted against the mold portions by expansion of the foam
mixture during the rise time is dependent upon the amount of foam
mixture applied and the reaction conditions. It is presently
preferred that foam mixture be applied in amount so the that the
reaction conditions result in a pressure against the mold portions
during the rise time between about 0.02 psi and 0.10 psi, and more
preferably between about 0.03 psi and 0.06 psi. Selection and
application of the foam mixture must also result in a dimensional
layer of the desired density.
[0083] Presently preferred polyurethanes include 3 lb.
FlexFoam-iT!.RTM. by Smooth-On.
[0084] The molding process can be carried out in a variety of ways,
depending on the requirements of the application. The basic
requirements are: (1) a dimension portion of the compression mold;
(2) a second portion of the compression mold, which may be flat as
in FIG. 2 or may itself be dimensional as in FIG. 8; (3) providing
an outer fabric layer; (4) providing foam mixture to form the
dimensional layer; (5) compressing the two portions of the mold
during the rise time; and (6) releasing the 3D fabric from the
mold.
[0085] Silicon molds may be used low volume applications of the
manufacturing process. For high volume applications, especially
where temperature control is critical, molds made of metals such as
aluminum are preferable.
EXAMPLES
Example 1
Fabric Testing
[0086] Various fabrics were tested for their suitability and
limitations for use in this invention. Referring to FIG. 4,
three-by-five inch patches of the fabrics to be tested ("fabric
test patches") 80 were arrayed on the surface of a flat lower mold
82. A dimensional mold was not used in these tests. Foam mixture 84
was prepared and applied to each of the squares in defined amounts
84. During the rise time, flat upper mold 86 was applied at a
defined pressure and for a second defined time (the "mold period").
The upper mold 86 was then removed, and each of fabric test squares
80 were scored on a scale of 1-10 (1=worst, 10=best) or otherwise
rated for stain resistance and bleed resistance, the thickness of
the dimensional layer was measured, and the pressure applied was
calculated. Tests were also performed without the upper mold being
applied (weight=0). Tests were done at room temperature. The
results of the tests are indicated in Table 1 below.
[0087] In Table 1, the following abbreviations are used as column
headings: [0088] In the notes column, G=no bleed-though or
staining, W=bleed-through, B=staining [0089] Grams=grams of foam
resin applied to the patch [0090] T=thickness of dimensional layer
[0091] Rise=rise period [0092] Mold=mold period [0093] Weight=total
weight of the upper mold portion (used to calculate pressure in
pounds/square inch or psi) [0094] SR=stain resistance (10 is best,
1 is worst) [0095] BR=bleed resistance (10 is best, 1 is worst)
[0096] TR=thread count of the fabric
TABLE-US-00001 [0096] TABLE 1 Fabric Test Results FABRIC TYPE notes
grams T rise mold weight SR BR TC Amerisuede G 3.4 1:50 7 MIN 0 10
10 Amerisuede G 3.4 1:50 7 MIN 2.5 10 10 Amerisuede W 3.4 1:50 7
MIN 7.85 80 2-Bar G 3.4 1:50 7 MIN 0 1 10 2-Bar G 3.4 1:50 7 MIN
2.5 1 10 2-Bar W 3.4 1:50 7 MIN 7.85# 1 10 80 Plain Weave B 3.4
1:50 7 MIN 0 10 10 Plain Weave G 3.4 1:50 7 MIN 2.5 10 10 Plain
Weave W 3.4 1:50 7 MIN 7.85 80 RT Twill 100 cot B 3.4 1:50 7 MIN 0
4 0 RT Twill 100 cot B 3.4 1:50 7 MIN 2.5 4 0 RT Twill 100 cot B
3.4 1:50 7 MIN 7.85 4 0 ? OL sweatshirt 100 poly W 3.4 1:50 7 MIN 0
OL sweatshirt 100 poly 3.4 1:50 7 MIN 0 0 OL sweatshirt 100 poly
3.4 1:50 7 MIN 7.85 0 0 0 Gen. Fleece 100 poly G 3.4 1:50 7 MIN 0
Gen. Fleece 100 poly B 3.4 1:50 7 MIN 2.5 Gen. Fleece 100 poly B
3.4 1:50 7 MIN 7.85 1 1 0 RT Jersey 100 cot B 3.4 1:50 7 MIN 0 RT
Jersey 100 cot W 3.4 1:50 7 MIN 2.5 RT Jersey 100 cot W 3.4 1:50 7
MIN 7.85 65 Gen. Knit 60 cot 40 poly W 3.4 1:50 7 MIN 0 Gen. Knit
60 cot 40 poly 3.4 1:50 7 MIN 2.5 Gen. Knit 60 cot 40 poly 3.4 1:50
7 MIN 7.85 100 RT Shirting 100 cot B 3.4 1:50 7 MIN 0 RT Shirting
100 cot W 3.4 1:50 7 MIN RT Shirting 100 cot W 3.4 1:50 7 MIN 7.85
65 MO Twill 55 cot 45 poly B 3.4 1:50 7 MIN 0 MO Twill 55 cot 45
poly B 3.4 1:50 7 MIN MO Twill 55 cot 45 poly B 3.4 1:50 7 MIN 7.85
60 RT brushed cot 100 cot W 3.4 1:50 7 MIN 0 RT brushed cot 100 cot
3.4 1:50 7 MIN RT brushed cot 100 cot 3.4 1:50 7 MIN 7.85 70 MO
Twill 7 oz 55 cot 45 po B 3.4 1:50 7 MIN 0 MO Twill 7 oz 55 cot 45
po B 3.4 1:50 7 MIN 2.5 MO Twill 7 oz 55 cot 45 po B 3.4 1:50 7 MIN
7.85 75 Gen. Heavy cot 100 cot B 3.4 1:50 7 MIN 0 Gen. Heavy cot
100 cot B 3.4 1:50 7 MIN 2.5 Gen. Heavy cot 100 cot B 3.4 1:50 7
MIN 7.85 90 Next Vista 8 oz cot 100 cot B 3.4 1:50 7 MIN 0 3 10
Next Vista 8 oz cot 100 cot W 3.4 1:50 7 MIN 2.5 3 10 Next Vista 8
oz cot 100 cot W 3.4 1:50 7 MIN 7.85 3 10 85 Vista Taslon ripstop
100 poly W 3.4 1:50 7 MIN 0 Vista Taslon ripstop 100 poly 3.4 1:50
7 MIN 2.5 Vista Taslon ripstop 100 poly 3.4 1:50 7 MIN 7.85 0 Nylon
trad. 100 nylon W 3.4 1:50 7 MIN 0 Nylon trad. 100 nylon 3.4 1:50 7
MIN 2.5 Nylon trad. 100 nylon 3.4 1:50 7 MIN 7.85 0 Bug Mesh
poly/nylon blend W 3.4 1:50 7 MIN 0 Bug Mesh poly/nylon blend 3.4
1:50 7 MIN 2.5 Bug Mesh poly/nylon blend 3.4 1:50 7 MIN 7.85 0 0 0
Glacier Gray Fleece 100 poly G 3.4 1:50 7 MIN 0 Glacier Gray Fleece
100 poly B 3.4 1:50 7 MIN 2.5 Glacier Gray Fleece 100 poly B 3.4
1:50 7 MIN 7.85 0 outerwear w/P.U. coat 100 poly G 3.4 1:50 7 MIN 0
outerwear w/P.U. coat 100 poly 3.4 1:50 7 MIN 2.5 outerwear w/P.U.
coat 100 poly G 3.4 1:50 7 MIN 7.85# 0 MO 65 poly 35 cot B 3.4 1:50
7 MIN 0 MO 65 poly 35 cot W 3.4 1:50 7 MIN 2.5 MO 65 poly 35 cot W
3.4 1:50 7 MIN 7.85 75 Tan Duck 100 cot (from B 3.4 1:50 7 MIN 0 6
6 Natalie) Tan Duck 100 cot (from W 3.4 1:50 7 MIN 2.5 6 6 Natalie)
Tan Duck 100 cot (from W 3.4 1:50 7 MIN 7.85 6 6 ? Natalie) Satin
(Outlier 1) -- 1:50 7 MIN -- -- -- ? Silk (Outlier 2) -- 1:50 7 MIN
-- -- -- ?
[0097] The test results showed that most of the fabrics varied
significantly (i.e., had bleed-through or staining) even without
the upper mold being applied. Others failed with a low pressure
(currently calculated to be about 0.03 psi) being applied. Most of
the fabrics tested failed at a high pressure (currently calculated
to be over 0.10 psi) being applied. Though the pressure applied may
be measured and calculated to classify fabrics as described in this
specification, fabric classification may also be done empirically
by comparison between fabrics.
[0098] FIG. 9A (not to scale) depicts an outer-side view of a third
embodiment of a 3D fabric 100. In the figure 3D fabric 100 has
essentially flat areas 102 of unmodified traditional fabric 102, as
well as "raised" or "3D" "veins" or "ridges" 104. FIG. 9B (not to
scale) depicts a cross-sectional area of a portion of FIG. 9A (with
the outer-side up). In FIG. 9B raised vein 104 is between two flat
areas 102. The flat areas 102 consist of a layer of traditional
outer fabric 102, while the raised vein 104 consists of an outer
layer of traditional fabric 102 as well as a "dimensional" or
"foam" layer 106. As viewed in FIG. 9B, the top side of traditional
fabric 102 is the "outer" side, which may be printed with a
(colored) pattern.
[0099] FIG. 10 shows the bottom-side view of a first embodiment of
a 3-D fabric 100. In the figure 3D fabric 100 has flat areas 102 as
well as veins/ridges 104 as in FIG. 9A. However, from this view it
is seen that the veins/ridges 104 are comprised of three separate
and discrete types of segments. Foam segments 106 have both
traditional fabric 102 as well as a foam layer 106, as depicted in
FIG. 9B. Spacer segments 108 have cross-sections as depicted in
FIG. 11. As can be seen in FIG. 11, the veins/ridges 104 of the
spacer segments 108 are comprised only of a traditional fabric 102
layer, with an air space 110. Spacer segments 108 occur between two
foam segments 106. The traditional fabric 102 in the spacer
segments 108 takes its 3D shape from the adjoining foam segments
106, which tend to keep the traditional fabric 102 in the spacer
segments 108 in a raised configuration. Referring now back to FIG.
10, it can be seen that the raised veins 104 are also comprised of
hubs 112, which are similar to the spacer segments 108 in that they
do not have a foam layer. However, hubs 112 occur at the
intersection of three or more foam segments 106.
[0100] The overall effect of this third embodiment of the 3D fabric
100 is to present an outer surface 102 with a 3D pattern of
ridges/veins 104, where the foam segments 106 are largely
indistinguishable from the spacer segments 108 and the hubs 112
because of the tendency of the foam segments 106 to hold the
traditional fabric 102 of the spacer segments 108 and the hubs 112
in a three-dimensional conformation.
[0101] The foam layer 106 is comprises a polymer foam. Polyurethane
is a preferred material. Polyurethane foams are forms from reacting
two components (isocyanate and polyol). When the two components are
mixed, a polymerization reaction occurs. The reaction includes a
period when the foam begins to expand and air pockets form. The
time from the mixing to the time of the foam reaching its largest
volume is the "rise time." After the rise time, the foam remains
tacky and problematic to handle for a period. The time from the
mixing to the time when the foam has lost its tackiness is called
the tack free time.
[0102] Because of the density and viscosity of the foam mixture, it
is preferable that the foam mixture be applied to the top of the
outer fabric layer during manufacturing. This can be done manually,
though mixing of the components of the foam mixture and application
of the foam mixture over the outer fabric layer are preferably done
by machine. A variety of mixing heads are presently available to
mix the components. Specialty automated processes and robots may be
designed to apply the foam mixture in desired amounts at particular
points depending on the desired product.
[0103] FIGS. 12-17 illustrate the manufacturing process for the
third embodiment of the 3D fabric 100. FIG. 12 shows the bottom
side of a portion of 3D fabric 102, similar to FIG. 10. The 3D
fabric 102 has flat areas 102, dimensional layer segments 104,
spacer segments 108 and hubs 112. Referring now to FIGS. 13A and
13B, mold 120 is seen from the top (FIG. 13A) and from the side
(FIG. 13B). Mold 120 is mostly planar, with grooves 122 where the
veins/ridges 104 will be formed. Mold 120 has flat areas 124 and
grooves 122. The grooves 122 may be of variable width and depth,
and need not be uniform.
[0104] The process begins by placing the outer fabric layer 102
pattern side down over the mold 120 and securing it in place. FIGS.
14A and 14B shows the fabric 102 held in place over the mold 120
from a top view (FIG. 14A) and side view (FIG. 14B). The dashed
lines in FIG. 14A indicate the outlines of the grooves 122. The
fabric 102 is held in place by fabric holders 126. By placing a
fabric holder 126 at both ends of a future foam segment, the fabric
102 is held against the mold for the length of the segment. FIG. 15
shows the foam segment 106 after the foam mixture has been applied
in the groove 122. The foam mixture is applied in the groove 122 in
an amount so that, after the rise time, the top of the foam
segments will be essentially level with the flat areas 102 of the
fabric. Fabric holders 126 remain in place until the tack free
time. At that time, the fabric holders 126 are removed from the
ends of the foam segment 106 (FIG. 16).
[0105] Manufacture of the 3D fabric 100 requires fitting an
essentially two dimensional traditional fabric 102 into a 3D shape
100. Stretching of the fabric 102 is not desirable because it may
make the fabric more porous and lead to bleeding and/or staining.
Another problem may be bunching of the fabric in certain areas,
resulting in a less appealing appearance. To reduce and avoid
stretching and bunching, it is sometimes desirable to form
different foam segments 106 in a sequence as opposed to forming all
of them at the same time. FIG. 17 illustrates this idea. Once foam
segment 106 has reached the tack free time and the fabric holders
126 are removed from the ends of that segment, fabric holders 126
are applied for a new foam segment area.
[0106] The essential function of the fabric holders 126 is to keep
the fabric 102 in contact with the groove 122 of the mold 120 when
forming a foam segment 106. Because of the tackiness of the foam
mixture before the tack free time, it is desirable to avoid the
foam mixture from contacting the fabric holders 126.
[0107] Fabric holders 126 can be designed in any configuration as
long as they perform their function. FIG. 18 depicts a variety of
fabric holders. FIG. 18A depicts the essence of a fabric holder
126, having a surface that holds the traditional fabric 102 against
the groove 122 in a mold 120. FIG. 18B depicts a fabric holder 126
having projections to hold it in place over a mold. FIG. 18C
depicts a fabric holder 126 with either a magnet or magnetic metal
130 in its projections. Such a fabric holder 126 may interact with
magnets or magnetic metals in the mold to hold it in place. FIG.
18D depicts a fabric holder 126 of a presently preferred
embodiment, in that the fabric holder is attached to an actuator
arm 128 which allows robotic control and movement of the fabric
holder. FIG. 18E depicts a fabric holder 126 in a configuration
that allows it to be used in grooves of various sizes. In this
embodiment, the business end of the fabric holder 126 may be
deformable. Other shapes and designs of fabric holders 126 may be
used in certain applications, e.g. holding the fabric 102 in hubs
112 where there is no uniform groove 122.
[0108] Manufacture of 3D fabrics 100 may be done by producing
individual sheets having defined sizes. For large scale production,
however, it is desirable that the manufacture of the 3D fabric 100
be performed in a continuous process, as shown in FIG. 19. The
process begins will a roll 136 of traditional fabric 102 and ends
with a roll 136 of 3D fabric 100. At the beginning of the process
the traditional fabric 102 is unrolled and placed on movable
molding table 138. Moveable molding table 138 may be comprised of
mold segments 140 that travel with the fabric 102 from point A to
point Z as the molding process is performed. As molding table 138
moves, mold segments 140 must be placed at or around point A and
removed at or around point Z. Along the way from point A to point
Z, at various other points (e.g. B, C, D, E), the steps shown in
FIGS. 14-17 are performed. The minimum time for the fabric 102 to
travel from point A to point Z is slightly longer than the tack
free time of the foam. However, because it is desirable to mold
foam segments in a staggered fashion, the time from point A to
point Z may be two or three times as long as the tack free time.
The use of increased temperatures and catalysts can speed the
polymerization process and reduce the time from point A to point
Z.
[0109] The operations shown in FIGS. 14-17 are performed from above
the molding table 138. They may be performed manually, but in a
preferable embodiment the operations are performed by computer
controlled robots and the foam mixture is dispensed and metered by
automatic mixers and applicators.
[0110] It is essential to the invention that the outer fabric layer
102 and the dimensional layer 106 are integrally bonded to each
other. Such bonding is achieved by the molding process. The outer
traditional fabric layer 102 is breathable and porous, allowing
adhesion of the fabric layer and foam mixture before the foam
mixture sets. When the foam mixture sets and forms the dimensional
layer 106, it also binds the dimensional layer 106 to the outer
fabric layer 102. The dimensional layer 106 is preferably
polyurethane. Polyurethane at a density of about or below three
pounds per cubic foot is a preferable material for its light
weight, washability, and durability. Presently preferred
polyurethanes include 3 lb. FlexFoam-iT!.RTM. by Smooth-On.
[0111] The polymer foam may be a closed-cell foam to deter the foam
from taking on moisture. The polymer foam may be breathable.
However, since the 3D fabric 100 has flat areas 102 without foam,
the overall fabric may still be breathable even though the foam
segments are not.
[0112] The hubs 112 and spacer segments 108 of the 3D fabric 100
allow for flexibility and comfort when the fabric is incorporated
into items of apparel. Without the hubs 112 and spacers 108, a
similar 3D fabric would be somewhat rigid. The hubs 112 and spacers
108, combined with relatively short vein segments 104, allow the
fabric to conform to the contours of the body and easily bend with
movement. Flexibility of the foam component also contributes to
flexibility of the overall 3D fabrics 100. Low density, flexible
foams are highly preferable to high density, rigid foams in this
regard. Example 2 describes stiffness testing of a preferred
embodiment of the invention. A k value may be calculated from the
example. It is presently preferable that the veins of the 3D
fabrics of the invention are between about 0.5 and 2.0 times the k
value in example 2.
Example 2
Stiffness Testing
[0113] A body may have a rotational stiffness, k, given by
k = M .theta. ##EQU00001##
where M is the applied moment .theta. is the rotation. (from
Wikipedia)
[0114] A prototype 3D fabric 100 having acceptable flexibility was
tested for stiffness. The vein segment 104 tested included the
outer fabric layer 102 and the foam layer 106. The vein segment 104
was about 1/4 inch in diameter (thickness) and 4 inches in length.
The fabric 102 was Amerisuede and the foam 106 was Flex Foam-It III
(Closed cell polyurethane 3 lb density). The vein segment was
easily compressible and bendable.
[0115] In the testing, one end of the vein segment 104 was secured
and the rest of the segment was unsupported. Quarters were placed
on the vein segment 104 two inches from the secured end and the
resulting bending was measured. The weight of each quarter was
about 5.67 grams. The first quarter resulted in a 5 degree angle.
Each subsequent quarter produced an additional 5 degrees of bending
as follows: 2 quarters=10 degrees, 3 quarters=15 degrees, etc. A
maximum of 6 quarters were added, which produced a 30 degree
angle.
[0116] When used for ordinary items of apparel, the 3D effect
invites touching. Softness of the outer fabric 102 is also
important to the invention. Preferable 3D fabrics 100 are soft to
the touch because of the qualities of the traditional fabric
layer.
[0117] 220 grams per square inch Amerisuede (universal name is
3-bar) having a brushed polyester outer layer is an acceptably soft
outer fabric. Preferable outer fabrics for use with the invention
are at least as soft as this fabric.
[0118] For applications where the prevention of bleed-through and
staining are important, preferred fabrics include: tightly-woven
synthetic microfibers, tightly-knit synthetic microfibers,
tightly-woven natural microfibers, tightly-knit natural
microfibers, and woven cotton/polyester blends with a thread count
above 150. "Tightly-woven" means impermeable to the foam mixture at
a rise-time pressure less than about 0.10 psi. Specifically
preferred fabrics include Ultrasuede and 100% polyester knit
fleece.
[0119] Silicon molds may be used for low volume applications of the
manufacturing process. For high volume applications, especially
where temperature control is critical, molds made of metals such as
aluminum are preferable.
[0120] The 3D fabrics 5, 26 and 100 of the invention are easily
sewable using conventional equipment, as the dimensional layer is
compressible during the sewing process. However, in some
applications where thick dimensional layers are desired in portions
of the fabric, it may be desirable to design and manufacture the
fabric to have thinner areas of the dimensional layer in accordance
with desired applications.
[0121] The 3D fabrics of the invention have a wide variety of
applications. They may be used for camouflage hunting apparel. They
may be used for military camouflage apparel. They may be used for
producing ordinary apparel (such as coats, pants, hats, shoes,
etc.) with interesting visual effects. They may be used for
producing ordinary apparel for their insulating properties. They
may be used for furniture coverings. They may be used in wall
coverings. They may be used in set designs. Specialty outer and
inner fabric layers may be incorporated for properties such as
sonic insulation, thermal insulation, heat retention, heat
reflectivity, indetectability to remote sensors (radar, sonar,
infra-red detectors, and the like). Electronics may be molded into
the dimensional layer for purposes of communication, monitoring of
body functions, lighting and the like). Other applications of the
fabrics will also become apparent over time.
[0122] The present invention includes materials and methods to
produce unique wearable three-dimensional (3-D) fabrics. The
fabrics comprise a dimensional layer made of foam and an outer
layer of traditional fabric, which may be patterned or dyed. The
dimensional layer may be molded to have contours matching the
pattern of the outer layer, with the resulting multilayer fabric
having both physical and graphical depth.
[0123] One application of this technology is to create camouflaged
clothing articles. For example, a suit comprising a jacket and
pants may have a tree or woods motif, where the fabric is
specifically contoured to provide physical depth to graphically
patterned branches and leaves. Preferably, the depth of the veins
of the 3D fabric varies from about 0.25 inches to about 4.0 inches,
and more preferably from about 0.25 inches to about 2.0 inches.
Outer fabric layer patterns may include trees, leaves, branches,
grassland vegetation, and the like. The patterns may be selected
from different types of outdoor environments: oak woods, pine
forests, maple forests, and the like.
[0124] In a presently preferred embodiment, the printed or
graphical patterns on the outer fabric layer are selected or
designed to match the physical depth of the 3D fabric, i.e., a
printed branch on the pattern will correspond with the shape of the
branch on the 3D fabric. This is useful for camouflage and other
applications. However, it is within the scope of the invention to
have 3D physical patterns that do not match the graphical
patterns.
[0125] In one aspect, the invention is a three-dimensional fabric
100 comprising: a traditional fabric outer layer 102; and a
dimensional layer 106 formed of polymer foam integrally bonded with
the outer layer 102, said dimensional layer 106 having a variable
thickness, where the 3D fabric 100 has flat areas without a
dimensional layer 106, vein segments 104 having a dimensional layer
106, and spacer segments 108 without a dimensional layer between
the vein segments. The dimensional layer 106 preferably has a
(optionally) variable thickness between about 0.25 and 4.0 inches.
The dimensional layer more preferably has a (optionally) variable
thickness between about 0.25 and 2.0 inches. The density of the
foam is preferably between about 1 and 4 pounds per cubic feet. The
density of the foam is more preferably between about 2.5 and 3.5
pounds per cubic feet. The stiffness of the vein segments 104 is
preferably between about 0.5 and 4 times the k value calculated
from example 1. The stiffness of the vein segments is more
preferably between about 0.5 and 2 times the k value calculated
from example 1. The vein segments 104 are preferably between about
1 and 8 inches in length. The vein segments 104 are more preferably
between about 2 and 5 inches in length. The spacer segments 108 are
preferably between about 0.5 and 2 inches in length. The spacer
segments 108 are more preferably between about 0.5 and 1 inch in
length. The outer layer 102 may plain-colored. The outer layer may
have be patterned. The pattern may have graphical depth. The
physical depth of the dimensional layer may match the graphical
depth of the pattern. The fabric may further comprise hub segments
112. The outer side of the traditional fabric layer is preferably
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.
[0126] A fourth embodiment of this invention's 3D fabric and method
of making is shown in FIGS. 20 through 30 and described hereat. The
method will be described first to appreciate how the fourth
embodiment is manufactured and its physical construction.
[0127] FIGS. 20 and 21 show master mold 200 is provided that is
generally 60 inches wide and 40 inches long. The mold 200 has a
base 204 with a vacuum chamber 206 therebelow. Chamber 206 has
vacuum inlets 214 where vacuum hoses may be secured to create a
vacuum in chamber 206. Approximately 17 flat and narrow steel bars
210 are secured to base 204 approximately 3.5 inches center to
center. Bars 210 provide a surface on base 204 for sonic welding
which will be appreciated below. Channels 212 are made in random
fashion in base 204. The welding bars 210 abut but do not pass over
channels 212. Vacuum ports 208 are in base 204, but not in channels
212, are in flow communication with vacuum chamber 206 therebelow
for securing fabric to the mold 200 during manufacturing.
[0128] Five top mold plates or a single plate 218 are shown in
FIGS. 22, 23 and 25. The bottom surface 220 (FIG. 22) of top mold
218 shows an array of slots 222 alignable with steel sonic welding
bars 210 and are also adjacent mold fingers 226. The fingers 226
are situated to seat into channels 212 of master mold 200 for
holding a fabric therein. Slots 222 provide alignable access to the
metal bars 210 for sonic welding which will be appreciated below.
Retainers 226 hold the channel mating fingers 224 in permanent
position. Handles 230 may be provided to place the top mold 218
into position on the master mold 200.
[0129] FIGS. 24 and 25 show the first position or station 252 of
the 3D fabric manufacturing process. A Camo fabric 234, as
previously described, is placed over master mold 200. Next top mold
in sections, or as a single plate 218, has its channel matting
fingers 226 lowered into channels 212 along with fabric 234.
Tapping or rocking of plate(s) 218 will assure that camo fabric 234
is completely pushed down into channels 212. In the case of a
single plate, as shown in FIG. 25, the plate 218 may be lifted or
lowered into position by cylinders 232 along arrow A. Next vacuum
is applied through inlets 214 and ports 208 to hold fabric 234 in
position. No vacuum is applied in channels 212 which would
interfere with this process. Thereafter the plate 218 is lifted
upwardly (arrow A) out of the way from master mold 200 with secured
channel formed outer fabric 234 in position for second station
262.
[0130] FIG. 26 shows the second position or station 262 of the 3D
fabric manufacturing process. The fabric liner 264 is positioned
over the secure outer fabric 234. Then the sonic welder 236 is
lowered (arrow B) by cylinders 242 to align welding heads 238 on
frame 240 to index upon steel bars 210 immediately adjacent to the
terminations of channel fingers 224 for welding the fabric liner to
the outer fabric at the steel bars which again are about 3.5 inches
center to center. Thereafter, welding heads 238 and frame 240 are
lifted upwardly (arrow B) and out of the way of finished 3D fabric
274. In the case where top mold 218 is not moved out of position,
welding may be accomplished through slots 222.
[0131] With the components understood, the assembly line 250 may
now be discussed. In the first position 252 (FIG. 27), the outer
(camo) fabric 234 is evenly dispensed from output roll 256 onto the
top of master mold 200 with the aid of idler or tension roller 258.
Then the preferable one piece top mold 218 is lowered by cylinders
232 onto the master mold 200 with channel fingers 224 indexed into
channels 212 thereby pushing the outer fabric 234 into the master
mold 200. A repeated punching motion of the mating fingers 224 into
channels 212 may be necessary to assure the outer fabric 234 in
properly located in channels 212. Then vacuum is applied to out
fabric 234 through ports 214 to lock the outer fabric 234 into
position. Thereafter, top mold 218 may be lifted out of the way
along arrow A by cylinders 232.
[0132] As shown in FIG. 28, cylinder 262 is actuated to move master
mold 200 to a second position or station 262 whereat liner fabric
264 is introduces from output roll 266 onto the top of outer fabric
234 with the aid of idler or tension roller 268. Next the fabric
sonic welder 236 on frame 240 is lowered (arrow B) into position by
cylinders 242 onto fabrics 234 and 264 positioned on master mold
200. By this arrangement, welding heads 238 are aligned in slots
220 touching the liner fabric 264, the outer fabric 234 therebelow
and the metal bars 210 below the fabrics 234 and 264. The weld is
next performed. Thereafter, the sonic welder assembly 236 is lifted
upwardly (arrow B) off the welded liner fabric 264 and away from
master mold 200. The vacuum is then turned off. The finished 3D
fabric 274 is then taken up onto windup roller 270 with the aid of
idler or tension roller 272. Lastly, the master mold 200 is moved
back to the first station 252 by cylinder 262 to have the assembly
process repeated.
[0133] FIGS. 29 and 30 illustrate the finished 3D fabric 274 with
ribs or tunnels 276 in the outer fabric 234 being held in place by
the positioning of sonic welds 278 between the outer and liner
fabrics 234 and 264. This is accomplished by the welds 278 being
placed about 3.5 inches apart. This distance may be adjusted for
different types of fabrics
[0134] A fifth embodiment of this invention's 3D fabric 300 and
method of making is shown in FIGS. 31 through 34 and described
hereat. The method will be described first to appreciate how the
fifth embodiment is manufactured and its physical construction.
Generally speaking, the fifth embodiment differs from the fourth
embodiment by way of its economical use of weldment of liner fabric
strips or fabric weldable or glueable tape strips 302.
[0135] FIGS. 31 and 33 show master mold 200 is provided that is
generally 60 inches wide and 40 inches long. The mold 200 has a
base 204 with a vacuum chamber 206 herebelow. Chamber 206 has
vacuum inlet 214 where vacuum hoses may be secured to create a
vacuum in chamber 206. Approximately 17 flat and narrow steel bars
210 are secured to base 204 approximately 3.5 inches center to
center. Bars 210 provide a surface on base 204 for sonic welding
which will be appreciated below. Channels 212 are made in random
fashion in base 204. The welding bars 210 abut but do not pass over
channels 212. Vacuum ports 208 are in base 204, but not in channels
212, are in flow communication with vacuum chamber 206 therebelow
for securing fabric to the mold 200 during manufacturing.
[0136] Five top mold plates or a single plate 218 are shown in
FIGS. 32 and 33. The plate 218 has an array of slots 222 alignable
with steel sonic welding bars 210 and are also adjacent mold
fingers 226. The fingers 226 are situated to seat into channels 212
of master mold 200 for holding a fabric therein. Slots 222 provide
alignable access to the metal bars 210 for sonic welding which will
be appreciated below. Retainers 226 hold the channel mating fingers
224 in permanent position.
[0137] FIGS. 31, 32 and 33 show the first step position of the
unfinished fifth embodiment of the 3D fabric 300 manufacturing
process. A camo fabric 234, as previously described, is placed
upside down over master mold 200 from output roll 256 while
contemporaneously, the fabric liner, 264, strips or fabric tape 302
is placed over the camo fabric 234 from output roll 267. Next top
mold single plate 218, has its channel matting fingers 226 lowered
into channels 212 along with fabric 234 until camo fabric 234 is
completely pushed down into channels 212. The plate 218 may be
lifted or lowered into position by cylinders 232 along arrow A.
Next vacuum is applied through inlets 214 and ports 208 to hold
fabric 234 in position. No vacuum is applied in channels 212 which
would interfere with this process.
[0138] FIG. 33 shows the second step of the 3D fabric 300
manufacturing process. In this method, there is no second station
250. The fabric liner 264 or 302 is already positioned over the
secured outer fabric 234. Then the sonic welder 236 is lowered
(arrow B) by cylinders 242 to align welding heads 238 on frame 240
to index upon steel bars 210 through slots 222 immediately adjacent
to the terminations of channel fingers 224 for welding the fabric
liner, strips or tape 263, 302 to the outer fabric at the steel
bars which again are about 3.5 inches center to center. Thereafter,
welding heads 238 and frame 240 are lifted upwardly (arrow B) and
out of the way of plate 218. Thereafter, plate 218 is lifted out of
the way of finished 3D fabric 300. The vacuum is then turned off
and the finished 3D fabric 302 may be taken up on finished roller
270.
[0139] Alternatively, single plate 218 or master mold 200 could be
heated to bond strips 302 to the outer fabric 234. If plates 218
were segmented, as previously described, tape or strips 302 could
be placed or positioned on top of the camo fabric 234 in the spaces
between and after plates 218 were placed on the mold 200.
[0140] FIG. 34 illustrate the finished 3D fabric 300 with ribs or
tunnels 276 in the outer fabric 234 being held in place by the
positioning of sonic welds 278 between the outer and liner fabrics
234 and 264 (or 302). This is accomplished by the welds 278 being
placed about 3.5 inches apart. This distance may be adjusted for
different types of fabrics
[0141] FIGS. 35 through 43 shows a sixth embodiment of the 3D
single layer synthetic fabric 405, 505 (FIG. 43) which visually
resembles the fifth embodiment 300 with outer fabric 234, 274
having ribs or tunnels 276. Generally speaking, the sixth
embodiment 405, 505 differs from the fifth embodiment 300 by way of
its economical use of a single-layer of 3D fabric 426, 526 and its
weldments 409, 509 upon itself to form tunnels or ribs 408, 508.
Again, fabrics applicable for this invention are typically
synthetic, which may include but are not limited to, polyester,
nylon, Lycra, spandex, nylon-elastane, denier coated nylon oxford
cloth, urethane and synthetic blends that lend themselves well to
welding together.
[0142] Referring to FIG. 35 through 38, the manual method of making
the sixth embodiment of the 3D fabric 405 (FIG. 43) may be
appreciated. The master mold forming plate 410 has a top side 412
with vacuum ports or channels 414 with a vacuum chamber 416
therebelow with a vacuum port 418 for creating a vacuum within
chamber 416. The master mold 410 maybe 60 inches long and 36 inches
wide. On the top side 412 are located curved forming blades or fins
420, suitably of different heights for making tall and short
tunnels 408. Alternatively, blades 420 may be substituted with
forming pins 422 of different heights arranged on the top 412 in a
curved fashion. Gaps for welding, fastening or otherwise attaching
single-layer synthetic fabric 426 are for fastening the fabric 426
to form tunnels 408 that will remain upward and distinct in
condition after weldment. Adjacent the opposite side of the master
mold forming plate 410 are located fabric feed roll 428 for
dispensing the fabric 426 across the mold plate 410 top side 412
and take up roll 430 for taking up the finished 3D single-layer
synthetic fabric 405.
[0143] In operation, the single-layer fabric 426 is taken off of
output or feed roll 428 and laid onto and across the master mold
410. The vacuum is then turned on. The operator uses his hands or
paddles to begin tucking the fabric 426 down onto the mold plate
410 adjacent the blades 420 or pins 422 as to create tunnels over
the blades 420 or pins 422. The operator starts at arrow A with
this process and proceeds toward the feed roll 428 tucking the
fabric 426 into place along arrows B, C, D, E, F, G and H. by this
method, more fabric 426 on feed roll 428 may be pulled off roll 428
as needed to form all the tunnels 408. Next the operator manually
welds or fastens the fabric together at weldments or tunnel bases
409 in all the gaps 424. This weldment will keep the tunnels 408
upright during use of the 3d single-layer synthetic fabric 405
which may be camouflaged to match the tunnels 408.
[0144] Ultrasound hand welding units may be obtained from Rinco
ULTRASONICS USA Incorporated, 87B Sand Pit Road, Danbury, Conn.
06810. Other welding techniques might include vibration welding,
heat welding, radio frequency (RF) welding or laser welding. RF
welders may be obtained from Amcraft RF Welding, 580 Lively
Boulevard, Elk Grove Village, Ill. 60007. Thereafter, the finished
3D fabric 434 is wound up onto windup or take up roll 430.
[0145] Thereafter the vacuum is stopped and the finished fabric 405
is taken up onto the take up roll as another section of fabric 426
is laid on the mold plate 410 top side 412 for repeating the
process.
[0146] Referring to FIGS. 39 through 42, an automated method of
making the sixth embodiment of the 3D fabric (FIG. 43) may be
appreciated. The master mold 510 has a top side 512 with tunnels or
channels 513 therebelow and through the mold 510 weld pockets
525.
[0147] Below the master mold 510 and separate therefrom are located
suitably five push plates 518A-E On top the plates 518A-E are
located curved forming blades or fins 520, suitably of different
heights for making tall and short tunnels 508. Alternatively,
blades 520 may be substituted with forming pins 522 of different
heights arranged on the push plates 518A-E in a curved fashion.
There are gaps 524 between the blades 520 and the pins 522 that are
suitably about 3.5 inches in width. The gaps 524 are alignable with
through the mold weld pockets 525 in the master mold 510. The
plates 518A-E are slidably mounted on guide pins 524 (only one
shown for simplicity of the FIG. 42). By this arrangement, blades
520 or pins 522 are assured to be in alignment with tunnels 513 as
the push plates 518A-E are moved up and down along arrow III.
[0148] Below the push plates 518A-E is movable lifting block 596
actuated to move up and down (arrow III) by action of a ram or
cylinder 600 which is horizontally movable (arrow IV) along rail
602 suitably by stepper motors (not shown). By this arrangement,
the push or lifting block 529 is alignable (arrow IV) below the
push plates 518A-E starting with 518A and lifting it upward (arrow
III) to index blades 520 or pins 522 into channels 513.
Alternatively, each push plate 518A-E could have their own fixed
and aligned lifting or push blocks 529 each with a fixedly mounted
cylinder 600 for sequentially lifting of push plate 518A-E.
[0149] In operation, the single-layer fabric 526 is taken off of
output or feed roll 528 and laid onto and across the push or lift
plates 518A-E just below the master mold 510. The lift block 529 is
indexed along the rail 602 just below lift plate 518A. The ram 600
is actuated to lift the lift block 529 and the first plate 518A. By
this action, the blades 520 are moved upward (arrow III) into a
locked position as to index the single layer fabric 526 up and into
the channels or tunnels 513 as more fabric 526 is pulled of the
feed roll 528. Next, the block 529 is lowered (arrow III) and moved
along rail 602 (arrow IV) as to index below under the next lifting
plate 518B. The block is then lifted (arrow III) and the next plate
518B moves upwardly as its blades 520 are moved upward (arrow III)
into a locked position as to further index more of the single layer
fabric 526 up and into the channels or tunnels 513. During this
action, more fabric 526 is pulled off the feed roll 528. This cycle
is repeated until plate 518E is lifted into position and more
fabric 526 is pulled of the feed roll 528.
[0150] Thereafter, welding is commenced in the through the mold
weld pockets 510 at tunnel bases 509 in the gap 524 areas either
with hand held welders or automated or robotic welding equipment.
Ultrasound welding heads may be obtained from Dukane Corporation,
2900 Dukane Drive, St. Charles, Ill. 60174. Again, Ultrasound hand
welding units may be obtained from Rinco ULTRASONICS USA
Incorporated, 87B Sand Pit Road, Danbury, Conn. 06810. Other
welding techniques might include vibration welding, heat welding,
radio frequency (RF) welding or laser welding. RF welders by be
obtained from Amcraft RF Welding, 580 Lively Boulevard, Elk Grove
Village, Ill. 60007. Thereafter, the finished 3D fabric 505 is
wound up onto windup or take up roll 530.
[0151] The finished 3D single-layer synthetic fabric 405, 505 is
ideal for use with camouflaged. fabric which further accentuates
the 3D effect particularly when the pattern is matched with the
tunnels to further effectuate the look of tree branches and the
like. Clothing and hunting blinds are such desirable examples.
[0152] While embodiments and applications of this invention have
been shown and described, it would be apparent to those skilled in
the art having the benefit of this disclosure that many more
modifications than mentioned above are possible without departing
from the inventive concepts herein. The invention, therefore, is
not to be restricted except in the spirit of the appended
claims.
* * * * *