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.

What is claimed is: 
     
         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.