Three dimensional fabrics with liner strips and assembly methods therefor

Abstract

3D fabrics have multiple layers including an outer dimensional layer of traditional fabric and a liner 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 outer dimensional layer while adhering it to the liner 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 synthetic fabric outer layer with outwardly extending random hollow tunnels therein; and   b. a liner layer of synthetic strips are adhered to an underside of the outer fabric layer adjacent to the tunnels.   
     
     
         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 adherences are formed by one of the following sonic welds, heat 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 , where an outer side of the outer 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. 
     
     
         10 . A three-dimensional fabric comprising:
 a. a synthetic fabric outer layer with outwardly extending random hollow tunnels therein; and   b. a synthetic fabric liner layer bonded to an underside of the outer fabric layer adjacent to the tunnels, wherein the three-dimensional fabric has flat areas and raised tunnel segments.   
     
     
         11 . The three-dimensional fabric of  claim 10 , where the tunnels have a variable height between about 0.25 and 4.0 inches. 
     
     
         12 . The three-dimensional fabric of  claim 10 , where the tunnels are curved and between about 1 and 60 inches in length. 
     
     
         13 . The three-dimensional fabric of  claim 10 , where the outer layer is plain-colored. 
     
     
         14 . The three-dimensional fabric of  claim 10 , where the outer layer has a pattern. 
     
     
         15 . The three-dimensional fabric of  claim 14 , where the pattern has graphical depth. 
     
     
         16 . The three-dimensional fabric of  claim 15 , where the raised tunnel segments of the outer layer match the graphical depth of the pattern. 
     
     
         17 . The three-dimensional fabric of  claim 10 , where an outer side of the outer fabric layer is at least as soft to the touch as 220 grams per square inch of Amerisuede (universal name is 3-bar) having a brushed polyester outer layer. 
     
     
         18 . A method of making a three-dimensional fabric, comprising:
 a) placing a synthetic fabric outer layer over a master mold having random channels thereon, parallel metal bars thereon that do not pass over the channels and vacuum ports thereon adjacent the channels and the bars:   b) placing a synthetic liner layer over the outer layer on the master mold;   c) lowering a top mold with depending fingers onto the master mold and outer fabric so that the depending fingers force the outer fabric into the channels;   d) applying vacuum to the ports to hold the outer fabric to the master mold;   e) bonding the liner layer to the outer layer at the metal bars adjacent to the channels to finish making the three-dimensional fabric;   f) raising the top mold away from the master mold;   g) stopping the vacuum; and   h) Removing the finished three-dimensional fabric from the master mold.   
     
     
         19 . The method of  claim 18 , where the bonds are chosen from a group comprising sonic welds, heat welds and adhesion and the bonds are approximately 3.5 inches apart. 
     
     
         20 . The three-dimensional fabric of  claim 18 , where the liner layer is chosen from a group comprising sonic a sheet of liner fabric, fabric welding tape or fabric strips. 
     
     
         21 . The three-dimensional fabric of  claim 19 , where the liner layer fabric welding tape or fabric strips are approximately 3.5 inches apart.