Molded fabric and methods of manufacture

Abstract

A novel molded fabric is made by bringing a first patterned group of numerous discrete disjoint elements positioned on a first side of a contact boundary extending throughout the thickness of the fabric being molded, together with a second patterned group of numerous discrete disjoint elements, over-lapping the first group of discrete disjoint elements, on the opposite side of the contact boundary, and joining the elements together at their tip portions. Various techniques are disclosed for maintaining separation of overlapping cross-over portions of the thread elements crossing each other during joining the terminal portions together, so that they simulate woven cloth. First and second rolls can carry the elements in molten form within cavities in the roller surfaces or patterns of solid elements within first and second matrices, can be joined together at the nip of the rolls by heat or chemical means to produce substantial savings in fabric manufacture.

I claim: 
     
         1 . A molded fabric having a given thickness and having first and second groups of overlapping threads joined together comprising:
 (a) a first group of numerous discrete disjoint elements positioned on a first side of a contact boundary extending through the thickness of said fabric being molded;   (b) a second group of numerous discrete disjoint elements positioned on a second side of said contact boundary opposite said first side;   (c) and wherein said numerous discrete disjoint elements are joined together at areas of contact of first and second groups of disjoint elements at said contact boundary and not at over-lapping and under-lapping crossings of portions of said first and second groups of discrete disjoint elements away from said areas of contact at said contact boundary.   
     
     
         2 . The molded fabric of  claim 1  wherein end portions of said numerous discrete disjoint elements of said first group are joined to end portions of numerous discrete disjoint elements of said second group. 
     
     
         3 . The fabric of  claim 1  wherein said fabric is made from a material that can be melt-joined by heat. 
     
     
         4 . The fabric of  claim 2  wherein said fabric is made from a material that can be melt-joined by heat. 
     
     
         5 . A molded fabric having a given thickness and having first and second groups of overlapping threads joined together comprising:
 (a) a first group of numerous discrete disjoint elements positioned on a first side of a contact boundary extending through the thickness of said fabric being formed;   (b) a second group of numerous discrete disjoint elements positioned on a second side of said contact boundary, opposite said first side; and   (c) and wherein said numerous discrete disjoint elements of said first and second groups are joined together at areas of contact at tips of said first and second groups of disjoint elements at said contact boundary and not at over-lapping and under-lapping crossings of portions of said first and second groups of disjoint elements away from said areas of contact at said contact boundary whereby said crossings do not form joints that stiffen the fabric.   
     
     
         6 . The fabric of  claim 5  wherein lengths of discrete disjoint elements in rows of said first group are positioned transversely with respect to lengths of disjoint elements in aligned facing rows of said second group. 
     
     
         7 . The fabric of  claim 6  wherein separator elements are provided for preventing joining together of said discrete disjoint elements at over-lapping and under-lapping crossings of portions of said first and second groups of disjoint elements away from said areas of contact at said contact boundary. 
     
     
         8 . The fabric of  claim 7  wherein said separator elements form a physical barrier positioned between said first and second groups of discrete disjoint elements at positions away from said areas of contact at said contact boundary. 
     
     
         9 . The fabric of  claim 8  wherein said physical barrier comprises an apertured film having apertures at said areas of contact where joining together of said groups of first and second discrete disjoint elements shall occur. 
     
     
         10 . The fabric of  claim 8  wherein said physical barrier comprises a set of elongated separator elements interleaved between said first and second groups of discrete disjoint elements. 
     
     
         11 . The fabric of  claim 7  wherein said separator elements comprise printed, painted, or sprayed patterns of anti-bonding agents. 
     
     
         12 . The fabric of  claim 1  wherein lengths of discrete disjoint elements in rows of said first group are positioned transversely with respect to lengths of disjoint elements in aligned facing rows of said second group. 
     
     
         13 . The fabric of  claim 12  wherein the lengths of discrete disjoint elements in rows of said first group are positioned at right angles with respect to the lengths of disjoint elements in aligned facing rows of said second group. 
     
     
         14 . The fabric of  claim 5  wherein lengths of discrete disjoint elements in rows of said first group are positioned transversely with respect to lengths of disjoint elements in aligned facing rows of said second group. 
     
     
         15 . The fabric of  claim 14  wherein the lengths of discrete disjoint elements in rows of said first group are positioned at right angles with respect to the lengths of disjoint elements in aligned facing rows of said second group. 
     
     
         16 . The fabric of  claim 1  wherein said discrete disjoint elements of said first and second groups of discrete disjoint elements are made of a material enabling said material to flow across said areas of contact upon being heated. 
     
     
         17 . The fabric of  claim 5  wherein said discrete disjoint elements of said first and second groups of discrete disjoint elements are made of a material enabling said material to flow across said areas of contact upon being heated. 
     
     
         18 . A fabric having a given thickness and having first and second groups of overlapping threads joined together comprising:
 (a) a first group of numerous discrete disjoint elements positioned on a first side of a contact boundary extending through the thickness of said fabric;   (b) a second group of numerous discrete disjoint elements positioned on a second side of said contact boundary opposite said first side;   (c) and wherein said numerous discrete disjoint elements are laminated together at areas of contact of first and second groups of disjoint elements at said contact boundary and not at over-lapping and under-lapping crossings of portions of said first and second groups of discrete disjoint elements away from said areas of contact at said contact boundary.   
     
     
         19 . The fabric of  claim 18  wherein said numerous discreet disjoint elements are heat laminated together. 
     
     
         20 . The fabric of  claim 18  wherein said numerous discreet disjoint elements are laminated together with a solvent.