Three dimensional fabrics

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.

What is claimed is: 
     
         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.