Spacer fabric

Abstract

A material comprises a cover layer and a porous material layer. The cover layer may include a rigid, semi-rigid or flexible material and the porous spacer material layer may include a reticulated foam, nonwoven textile, or a spacer fabric. The material is configured to have a high air flow rate upon an application of a pressure, and good compactability.

1 . A material, comprising: 
 a first fabric layer;    a second fabric layer; and    a pile layer extending between the first fabric layer and the second fabric layer,    wherein the pile layer is configured so that when the material is subjected to air pressure of 200 mBar, the air flow rate through the pile layer is in the range of approximately 80 to 300 cfm.    
   
   
       2 . The material of  claim 1 , wherein the air flow rate is in the range of approximately 200 to 250 cfm.  
   
   
       3 . The material of  claim 2 , wherein the air flow rate is approximately 214 cfm.  
   
   
       4 . The material of  claim 1 , wherein the pile layer is configured to maintain the flow rate when compressed up to approximately 40% original loft.  
   
   
       5 . The material of  claim 1 , further comprising a cover layer.  
   
   
       6 . The material of  claim 5 , wherein the cover layer is laminated to the first layer or second layer.  
   
   
       7 . The material of  claim 5 , wherein the pile layer is configured to maintain the flow rate when the material is subjected to a force of 150 pounds applied to the cover layer.  
   
   
       8 . The material of  claim 5 , wherein the material is configured so that when the material is subjected to air pressure of 200 mBar and a force of at least 200 pounds is applied to the cover layer the air flow rate through the porous layer is at least 100 cfm.  
   
   
       9 . A material, comprising: 
 a porous material layer including a plurality of fibers extending between a pair of fabric layers,    wherein each of the fibers has a tenacity in the range of approximately 40 to 50 cN/tex.    
   
   
       10 . The material of  claim 9 , wherein each of the fibers has a diameter in the range of approximately 0.07 to 0.11 mm.  
   
   
       11 . The material of  claim 10 , wherein each of the fibers has a diameter in the range of approximately 0.08 to 0.10 mm.  
   
   
       12 . The material of  claim 11 , wherein each of the fibers has a diameter of approximately 0.09 mm.  
   
   
       13 . The material of  claim 9 , wherein each of the fibers is configured to have a tenacity of approximately 43 to 48 cN/tex.  
   
   
       14 . The material of  claim 13 , wherein the plurality of fibers are configured to have a tenacity of approximately 46 cN/tex at for a diameter of approximately 0.09 mm.  
   
   
       15 . The material of  claim 9 , further comprising a cover layer.  
   
   
       16 . The material of  claim 15 , wherein the cover layer is laminated to one of the fabric layers.  
   
   
       17 . The material of  claim 9 , wherein each of the plurality of fibers is a monofilament fiber.  
   
   
       18 . A material, comprising: 
 a porous material layer including a plurality of fibers extending between a pair of fabric layers, and    wherein each of the fibers has a diameter in the range of approximately 0.07 to 0.11 mm.    
   
   
       19 . The material of  claim 18 , wherein each of the fibers has a diameter in the range of approximately 0.08 to 0.10 mm.  
   
   
       20 . The material of  claim 19 , wherein each of the fibers has a diameter of approximately 0.09 mm.  
   
   
       21 . A material, comprising: 
 a first fabric layer;    a second fabric layer; and    a pile layer extending between the first fabric layer and the second fabric layer,    wherein the material is configured to have a specific compactability in the range of 35 to 100 cm 3 .    
   
   
       22 . The material of  claim 21 , wherein the material is configured to have a specific compactability in the range of 40 to 90 cm 3 .  
   
   
       23 . The material of  claim 22 , wherein the material is configured to have a specific compactability in the range of 45 to 80 cm 3 .  
   
   
       24 . The material of  claim 21 , further comprising a cover layer.  
   
   
       25 . The material of  claim 21 , wherein the cover layer is laminated to the first layer or second layer.