Film three-dimensional mesh fabric and its manufacturing method

A method of manufacturing a film three-dimensional mesh fabric has steps of preparing a base cloth, preparing a mesh fabric, preparing a hot-melt film, providing the mesh fabric on the base cloth, providing the hot-melt film on the mesh fabric, heating, compressing and sagging a part of the hot-melt film into a plurality of grids and attaching the part to the base cloth so as to form a sagged portion and a plurality of insert holes, tearing off the base cloth, removing the sagged portion, and generating the film three-dimensional mesh fabric having the mesh fabric, a remaining part of the hot-melt film attached to the mesh fabric without sagging into the plurality of grids and without being attached to the base cloth and the plurality of insert holes corresponding to the plurality of grids and formed on the hot-melt film.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to a fabric manufacturing method, particularly to a film three-dimensional mesh fabric and its manufacturing method.

2. Description of the Prior Art

A conventional mesh fabric structure is generally made by having a plurality of yarns twisted together and then woven criss-cross in warp and weft direction, having a plurality of breathable grids formed among the woven threads, and such mesh fabric can be widely used for shoes, clothing and sporting goods. In addition, in order to cater to consumers who are particular about quality of life and styles for stimulating consumer's desire of purchase, the conventional mesh fabric structure usually carries out dyeing treatment after woven into shape for presenting colorful designs so as to attract attention of the consumers.

However, the conventional mesh fabric structure is to carry out dyeing treatment after woven into shape; therefore, its color saturation is of lower grade, its color is not full and the change of color is monotonous, thus unable to meet consumers' needs of innovation and variety. Further aside from unchanged color, the conventional mesh fabric structure is unable to increase other variability and functionality, such as variation of material or increase of reflection design. Therefore, the inventor of this invention observes the above-mentioned drawbacks and thinks that the conventional mesh fabric structure needs to be ameliorated and hence devises this invention.

SUMMARY OF THE INVENTION

The objective of this invention is to offer a film three-dimensional mesh fabric and its manufacturing method, able to have a mesh fabric additionally provided thereon with a hot-melt film by which the mesh fabric can enhance its variability and functionality of the mesh fabric.

The film three-dimensional mesh fabric in the present invention includes a mesh fabric having its surface provided with a plurality of grids. A hot-melt film is stuck to at least one side of the mesh fabric and provided with a plurality of insert holes at locations corresponding to the grids of the mesh fabric.

The manufacturing method of a film three-dimensional mesh fabric in the present invention includes the following steps: A first step is to prepare a base cloth having its surface provided with a mesh fabric, which has another side opposite to the base cloth provided with a hot-melt film, thus completing a first semi-finished product, wherein the mesh fabric has its surface formed with a plurality of grids. A second step is to have the first semi-finished product heated and compressed such that a portion of the hot-melt film, corresponding to the grid, sags into the grid and is tightly attached to the base cloth to form a sagged portion, such that the surface of the hot-melt film is formed into a plurality of insert holes corresponding with the shape of the grids, thus completing a second semi-finished product. A last step is to tear off the base cloth from the second semi-finished product and remove the sagged portion of the hot-melt film, which sags into the grid and stuck to the base cloth, such that the mesh fabric is formed thereon with the hot-melt film, which is provided with a plurality of insert holes at locations corresponding to the grids, thus completing a finished product of a film three-dimensional mesh fabric.

The film three-dimensional mesh fabric and its manufacturing method in the present invention is first to make a portion of the hot-melt film, which corresponds to the grid of the mesh fabric, sags into the grid and is stuck to the base cloth and then tears off the base cloth and remove the sagged portion that sags into the grid and is stuck to the base cloth, such that the mesh fabric is formed thereon with the hot-melt film, which is formed with a plurality of insert holes corresponding to the grids. By so designing, the mesh fabric can be additionally provided with the hot-melt film and retain its original grids and thus, the hot-melt film enables a user to carry out designs of variety of colors, materials and function for enhancing variability and functionality of the mesh fabric.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

A preferred embodiment of a manufacturing method of a film three-dimensional mesh fabric10in the present invention, as shown inFIGS. 1 and 2, is orderly provided with a discharge unit20, a hot-press unit30, a cooling unit40and a collecting unit50arranged in a conveying direction, and includes the following steps:

A first step is to have a base cloth discharge wheel21discharging a base cloth11and have a mesh fabric discharge wheel22discharging a mesh fabric12and then employ a first auxiliary roller set23to have the mesh fabric12tightly attached to the base cloth11with a temperature of 20° C. to 60° C. Afterward, have a film discharge wheel24discharging a hot-melt film13and employ a second auxiliary roller set25to have the holt-melt film13tightly stuck to the mesh fabric12at one side opposite to the base cloth11with a temperature of 60 t to 180° C., thus completing a first semi-finished product101. The base cloth11can adopt T/C cloth (tetoron/cotton cloth), tetoron, nelon, synthetic fiber, acrylic fiber, cotton, linen, silk, elastic fiber or non-woven fabric. The mesh fabric12is made by having a plurality of weaving threads121woven together, having a plurality of grids formed among the weaving threads121, and the mesh fabric12can adopt tetoron, nelon, synthetic fiber, acrylic fiber, cotton, linen, silk, elastic fiber or non-woven fabric. The hot-melt film13can adopt polyurethane, thermoplastic polyurethane, metal film, biaxial stretching polypropylene film, low density polyethylene film, nelon film, casting polypropylene film, polyvinyl chloride, polyethylene, polystyrene, polyester film, polypropylene, or nelon film.

A second step is to have the semi-finished product101blown with hot air by a hot air blower with a temperature of 40° C. to 200° C. for preheating and softening the hot-melt film13to attain effect of preliminary shaping and positioning and then carries out heating and pressurizing with a temperature of 60° C. to 180° C. A hot-press roller set32can be employed to carry out heating and pressurizing by having an upper roller and a lower roller rolled and pressed oppositely to carry out thermo-compression, or a hot-press forming mold33can be employed to carry out heating and pressurizing by having an upper mold and a lower mold pressed fit to carry out hot compression. Preferably, the hot-press roller set32is first employed to carry out hot compression for a first time and then has the hot-press forming mold33carrying out hot compression for a second time, and additionally has a vacuum pump34vacuumizing the hot-press forming mold33, such that the pressure in the hot-press forming mold33maintains between-2 bar and 2 bar. Thus, a part of the hot-melt film13, corresponding to the grids122, will sags into the grids122and will be tightly attached to the base cloth11to form a sagged portion131, such that the surface of the hot-melt film13forms a plurality of insert hole132corresponding with the shape of the grids12and thus completing a second semi-finished product102.

A last step is to have the second semi-finished product102cooling off via a cooler41with a temperature of −40° C. to 30° C. and then employ a cooling clamping roller set42to have the second semi-finished product102conveyed to the collecting unit50to have a first finished product collecting wheel51rolling up the mesh fabric12and the hot-melt film13and employ a second finished product collecting wheel52to roll up the base cloth11. Thus, the base cloth11is torn off from the second semi-finished product102and the sagged portion131sagging in the grids122and stuck to the base cloth11is removed, such that the mesh fabric12is formed thereon with the holt-melt film13, which is formed with the insert holes132corresponding to the grids122, thus completing a finished product of a film three dimensional mesh fabric10.

Referring toFIGS. 3 and 4, the hot-press roller set32has its surface annularly provided with a wheel sticking soft pad321, while the hot-press forming mold33has an upper side and a lower side respectively provided with a mold soft pad331corresponding to the first semi-finished product101, and a silica gel soft pad332is sandwiched in each mold soft pad331. By so designing, when the hot-press roller set32and the hot-press forming mold33carry out thermo-compression to the first semi-finished product101, the wheel sticking soft pad321and the mold soft pad331, which are able to be deformed elastically, can really have the portions of the hot-melt film13, corresponding to the grids122, compressed in the grids122. Thus, not only the shape of the grids122can be completely presented, but also the locations of the hot-melt film13, which correspond to the woven threads121of the mesh fabric12, can be compressed to present the original patterns of the woven threads121, and the above-mentioned effects will become more evident if the vacuum pump34can be additionally employed to carry out vacuumization.

Referring toFIGS. 5 and 6, the film three-dimensional mesh fabric10manufactured through above-mentioned manufacturing method contains the mesh fabric12having its surface formed with a plurality of grids122and having at least one side stuck with the hot-melt film13, which is provided with a plurality of insert holes132corresponding with the grids122. By so designing, the mesh fabric12can be additionally provided thereon with the hot-melt film13and retains the original grids122of the mesh fabric12and thus, a user can carry out design in variety of colors, material and function via the hot-melt film13for enhancing changeability and functionality of the mesh fabric12. For instance, the hot-melt film13can be designed to form metal pattern for building decoration changes of different materials, or the hot-melt film13can be a reflective material to render the film three-dimensional mesh fabric formed with reflective functionality.

Referring toFIG. 2, one special feature of this invention is that the base cloth11torn off from the second semi-finished product102and rolled up by the second finished product collecting wheel52has its surface retaining the sagged portions131that sag into the grids122and tightly attached to the base cloth11, such that the surface of the base cloth11is formed into three-dimensional patterns corresponding with the arrangement and shape of the grids122to enable the base cloth11to be recycled and re-used for article decoration, such as shoes, clothing or handbags. Therefore, the manufacturing method of a film three-dimensional mesh fabric of this invention is able to fully make use of all the materials and has environmental protection and economic benefits.