Continuous manufacturing equipment of elastic three-dimensional fabric and continuous manufacturing method thereof

A continuous manufacturing equipment of an elastic three-dimensional fabric and a continuous manufacturing method thereof are disclosed. The continuous manufacturing equipment includes: a film conveying device having a thermal melting film and a conveying mechanism; a cutting device used for cutting a plurality of cutting gaps on the thermal melting film; a first fabric laminating device adhering an outer fabric on one surface of the thermal melting film; and a second fabric laminating device adhering an elastic fabric on another surface of the thermal melting film in a manner of elastically stretching and then elastically recovering. As such, effects of automatic, continuous, and simple steps in manufacturing and having a high yield rate are provided.

BACKGROUND OF THE DISCLOSURE

Technical Field

The present disclosure relates to a manufacturing equipment of a fabric and a continuous manufacturing method thereof, particularly to a continuous manufacturing equipment of an elastic three-dimensional fabric and a continuous manufacturing method thereof

Description of Related Art

A related-art three-dimensional fabric having elasticity is commonly applied in various textiles, for example clothing, shoes, bags, domestic decorations, and the interior decorations of a vehicle, to enhance and express the personal style. The three-dimensional fabric having elasticity is manufactured through a male mold and a female mold being thermally pressed for formation.

However, the molding formation method has disadvantages as follows. The production cost is high because the male mold and the female mold are required. An automated continuous manufacturing may not be provided. The fabric surface of finished product is hard and a comfortable touching feeling may not be provided. Defects and pressed marks are easily formed and the elastic recovering rate is poor. The finished product may be deformed after being stretched and water washed.

Accordingly, the applicant of the present disclosure has devoted himself for improving the mentioned disadvantages.

SUMMARY OF THE DISCLOSURE

The present disclosure is to provide a continuous manufacturing equipment of an elastic three-dimensional fabric and a continuous manufacturing method thereof. As such, the elastic three-dimensional fabric may be automatically and continuously manufactured with the continuous manufacturing equipment and the continuous manufacturing method to achieve effects of automatic, continuous, and simple steps in manufacturing and having a high yield rate.

Accordingly, the present disclosure provides a continuous manufacturing equipment of an elastic three-dimensional fabric, which includes: a film conveying device, having a thermal melting film and a conveying mechanism used for sequentially conveying the thermal melting film to pass a processing zone, a first laminating zone and a second laminating zone; a cutting device, disposed in the processing zone and used for cutting a plurality of cutting gaps on the thermal melting film; a first fabric laminating device, disposed in the first laminating zone and having a first feeding wheel, a first thermal pressing wheel and an outer fabric, one end of the outer fabric is reeled in the first feeding wheel and another end thereof is stacked on the thermal melting film to be thermally laminated via the first thermal pressing wheel to adhere the outer fabric on one surface of the thermal melting film; and a second fabric laminating device, disposed in the second laminating zone, and having a second feeding wheel, a second thermal pressing wheel, a drive wheel and an elastic fabric, one end of the elastic fabric is reeled in the second feeding wheel and another end thereof is stacked on the thermal melting film to be thermally laminated via the second thermal pressing wheel, the drive wheel is disposed between the second feeding wheel and the second thermal pressing wheel and abuts against the elastic fabric, a rotation speed of the second thermal pressing wheel is greater than a rotation speed of the drive wheel to adhere the elastic fabric on another surface of the thermal melting film in a manner of elastically stretching and then elastically recovering.

Accordingly, the present disclosure provides a continuous manufacturing method of an elastic three-dimensional fabric, which includes steps of: a) providing a film conveying device, having a thermal melting film and a conveying mechanism used for sequentially conveying the thermal melting film to pass a processing zone, a first laminating zone and a second laminating zone; b) providing a cutting device, disposed in the processing zone and used for cutting a plurality of cutting gaps on the thermal melting film to form a pattern texture between the plurality of the cutting gaps on the thermal melting film, and each of the cutting gaps having a slit; d) providing a first fabric laminating device, disposed in the first laminating zone and having a first feeding wheel, a first thermal pressing wheel and an outer fabric, one end of the outer fabric being reeled in the first feeding wheel and another end thereof being stacked on the thermal melting film to be thermally laminated via the first thermal pressing wheel to adhere the outer fabric on one surface of the thermal melting film; e) providing a second fabric laminating device, disposed in the second laminating zone, and having a second feeding wheel, a second thermal pressing wheel, a drive wheel and an elastic fabric, one end of the elastic fabric being reeled in the second feeding wheel and another end thereof being stacked on the thermal melting film to be thermally laminated via the second thermal pressing wheel, the drive wheel being disposed between the second feeding wheel and the second thermal pressing wheel and abutting against the elastic fabric, a rotation speed of the second thermal pressing wheel being greater than a rotation speed of the drive wheel to adhere the elastic fabric on another surface of the thermal melting film in a manner of elastically stretching and then elastically recovering; and f) the elastic fabric being elastically recovered after being released from the second thermal pressing wheel to drive the slit of each of the cutting gaps to be shrunk, thus the elastic fabric being formed with a flat surface adhered on the pattern texture and arranged corresponding to the plurality of cutting gaps, and the outer fabric being formed with a flat adhering part adhered on the pattern texture and a plurality of three-dimensional embossed patterns arranged corresponding to the plurality of cutting gaps and protruding through each of the slits being shrunk.

Based on what has been disclosed above, with the continuous manufacturing equipment of the elastic three-dimensional fabric and the continuous manufacturing method thereof provided by the present disclosure, and a mold-less formation is achieved, the continuous manufacturing equipment and the continuous manufacturing method are provided with effects of being automatic, continuous, and simple steps in manufacturing and having a high yield rate.

Based on what has been disclosed above, advantages achieved by the present disclosure are as follows. There is no mold pressed mark or defect formed on the elastic three-dimensional fabric provided by the present disclosure. The thermal melting film may still be tightly adhered with the outer fabric and the elastic fabric after being washed with water of a temperature equal to or lower than 40° C. The stretching recovery rate of the thermal melting film itself is high and the peeling strength after being adhered may reach a value equal to or more than 2 Kg/cm2, thus the elastic three-dimensional fabric is provided with advantages of increasing the three-dimensional level and having a desirable elastic recovering rate.

DETAILED DESCRIPTION OF THE DISCLOSURE

Please refer fromFIG.1toFIG.4, the present disclosure provides a continuous manufacturing equipment of an elastic three-dimensional fabric and a continuous manufacturing method thereof. The continuous manufacturing equipment10mainly includes a film conveying device1, a cutting device2, a first fabric laminating device3and a second fabric laminating device4.

Please refer toFIG.2, which discloses the continuous manufacturing method of the elastic three-dimensional fabric100. Firstly, as shown in a) ofFIG.2andFIG.1, a film conveying device1is provided. The film conveying device1has a thermal melting film12and a conveying mechanism14. The thermal melting film12sequentially passes a processing zone h1, a first laminating zone h2and a second laminating zone h3via the conveying mechanism14.

Moreover, the film conveying device1further has a film roller11. One end of the thermal melting film12is reeled in the film roller11and another end thereof is conveyed via the conveying mechanism14. In some embodiments, the conveying mechanism14has a plurality of conveying wheel sets141, but here is not intended to be limiting.

The thermal melting film12is made of the material such as thermoplastic polyurethanes (TPU) or ethylene vinyl acetate (EVA). The thermal melting film12is an adhesive which is melted when being heated and solidified when being cooled. The thermal melting film12has a desirable adhering strength under a proper temperature. An extending rate of the thermal melting film is 100% to 500%.

Secondly, as shown in b) ofFIG.2andFIG.1andFIG.3, a cutting device2is provided. The cutting device2is disposed in the processing zone h1. The thermal melting film12is cut to form a plurality of cutting gaps121via the cutting device2, thus the thermal melting film12has a pattern texture122disposed between the plurality of cutting gaps121. Each of the cutting gaps121has a slit s. The cutting device2is a laser cutting device or a rolling cutting device.

Thirdly, as shown in c) ofFIG.2andFIG.1, a removing device5is provided. The removing device5is disposed between the processing zone h1and the first laminating zone h2. Waste materials generated when the thermal melting film12is cut by the cutting device2are removed via the removing device5.

Fourthly, as shown in d) ofFIG.2andFIG.1, a first fabric laminating device3is provided. The first fabric laminating device3is disposed in the first laminating zone h2. The first fabric laminating device3has a first feeding wheel31, a first thermal pressing wheel32and an outer fabric33. One end of the outer fabric33is reeled in the first feeding wheel31and another end thereof is stacked on the thermal melting film12to be thermally pressed via the first thermal pressing wheel32, thus the thermal melting film12has a heat reactivity to be adhered with the outer fabric33, and the outer fabric33is adhered on one surface of the thermal melting film12.

Fifthly, as shown in e) ofFIG.2andFIG.1, a second fabric laminating device4is provided. The second fabric laminating device4is disposed in the second laminating zone h3. The second fabric laminating device4has a second feeding wheel41, a second thermal pressing wheel42, a drive wheel43and an elastic fabric44. One end of the elastic fabric44is reeled in the second feeding wheel41and another end thereof is stacked on the thermal melting film12to be thermally pressed via the second thermal pressing wheel42. The drive wheel43is disposed between the second feeding wheel41and the second thermal pressing wheel42and abuts against the elastic fabric44. A rotation speed of the second thermal pressing wheel42is greater than a rotation speed of the drive wheel43, thus the elastic fabric44is first elastically stretched and then elastically recovered to be adhered on another surface of the thermal melting film12.

With the difference between the rotation speed of the second thermal pressing wheel42and the rotation speed of the drive wheel43, the elastic fabric44is stretched to be an extending rate equal to or more than 20%, in other words a length of the elastic fabric44is stretched to 1.2 times longer than an original length of the elastic fabric44, and the stretched elastic fabric44is adhered on another surface of the thermal melting film12.

In addition, a thickness of the thermal melting film12is 0.05 to 0.2 mm to prevent the thermal melting film12from being too thin to achieve an adhering function. If the thermal melting film12is overly thick, the thermal melting film12may leak out to an outer surface of the outer fabric33and an outer surface of the stretched elastic fabric44.

Sixthly, as shown in0ofFIG.2andFIG.1andFIG.4, the elastic fabric44is elastically recovered after being released from the second thermal pressing wheel42to drive the slit s of each of the cutting gaps121to be shrunk, thus the elastic fabric44is formed with a flat surface441adhered on the pattern texture122and arranged corresponding to the plurality of cutting gaps121, and the outer fabric33is formed with a flat adhering part331adhered on the pattern texture122and a plurality of three-dimensional embossed patterns332arranged corresponding to the plurality of cutting gaps121and protruding through each of the slits s being shrunk.

Details are provided as follows. The elastic fabric44is elastically recovered from the stretched status to the original status after the elastic fabric44is released from the second thermal pressing wheel42, the elastic fabric44is formed with the flat surface441adhered on the pattern texture122and arranged corresponding to the plurality of cutting gaps121, thus the elastic fabric44and the pattern texture122of the thermal melting film12are adhered and fixed. The elastic fabric44may only be elastically recovered through the slits s of the plurality of cutting gaps121, and the slit s of each of the cutting gaps121is driven to be shrunk.

In addition, the outer fabric33is adhered and fixed with the pattern texture122of the thermal melting film12, when the slit s of each of the cutting gaps121is shrunk, the flat adhering part331of the outer fabric33is in a surface flattening status due to being adhered and fixed with the pattern texture122, and the plurality of three-dimensional embossed patterns332of the outer fabric33are outwardly protruded because each of the slits s is shrunk.

As such, the elastic fabric44is firstly elastically stretched and then elastically recovered to be adhered on the another surface of the thermal melting film12to make the slit s of each of the cutting gaps121be shrunk, thus the outer fabric33having the plurality of three-dimensional embossed patterns332is formed.

Seventhly, as shown in g) ofFIG.2andFIG.1, a finished product reeling wheel6is provided. The outer fabric33, the thermal melting film12and the elastic fabric44are laminated up and down to form the three-dimensional fabric100. The finished product reeling wheel6is disposed at one side of the second laminating zone h3away from the first laminating zone h2. The finished product reeling wheel6is used for reeling the elastic three-dimensional fabric100.

Moreover, the film conveying device1further has two release papers13adhered on a top surface and a bottom surface of the thermal melting film12, a first recycling roller15disposed between the removing device5and the first thermal pressing wheel32, and a second recycling roller16disposed between the first thermal pressing wheel32and the second thermal pressing wheel42. One end of one of the release papers13is reeled in the film roller11and another end thereof is reeled in the first recycling roller15, thus the thermal melting film12is adhered and fixed with the outer fabric33after the release paper13on one surface of the thermal melting film12is peeled off. One end the other release paper13is reeled in the film roller11and another end thereof is reeled in the second recycling roller16, thus the thermal melting film12is adhered and fixed with the elastic fabric44after the release paper13on another surface of the thermal melting film12is peeled off.

In addition, the continuous manufacturing equipment10of the present disclosure further includes a plurality of direction turning wheels7used for turning a moving direction of the thermal melting film12and the outer fabric3which are mutually laminated, and a plurality of fans8. The fans are disposed between the first thermal pressing wheel32and the second thermal pressing wheel42and arranged corresponding to the thermal melting film12and the outer fabric33which are mutually laminated, and disposed between the second thermal pressing wheel42and the finished product rolling wheel6and arranged corresponding to the elastic three-dimensional fabric100. The fan8is used for generating an airflow to cool the thermal melting film12.

Accordingly, the elastic three-dimensional fabric100may be continuously manufactured with the continuous manufacturing equipment10and the continuous manufacturing method provided by the present disclosure, and a mold-less formation is achieved, the continuous manufacturing equipment10and the continuous manufacturing method are provided with effects of being automatic, continuous, and simple steps in manufacturing and having a high yield rate.

Moreover, advantages achieved by the present disclosure are as follows. There is no mold pressed mark or defect formed on the elastic three-dimensional fabric100provided by the present disclosure. The thermal melting film12may still be tightly adhered with the outer fabric33and the elastic fabric44after being washed with water of a temperature equal to or lower than 40° C. The stretching recovery rate of the thermal melting film12itself is high and the peeling strength after being adhered may reach a value equal to or more than 2 Kg/cm2, thus the elastic three-dimensional fabric100is provided with advantages of increasing the three-dimensional level and having a good elastic recovering rate.

Please refer toFIG.5andFIG.6, which disclose another embodiment and one another embodiment of the thermal melting film2provided by the present disclosure. The another embodiment and the one another embodiment disclosed inFIG.5andFIG.6are substantially the same as the embodiment disclosed inFIG.3. The difference between the another embodiment and the one another embodiment disclosed inFIG.5andFIG.6and the embodiment disclosed inFIG.3is the pattern design of the pattern texture122. The pattern texture122shown inFIG.3is composed of a plurality of rhombus-shaped surfaces being arranged in parallel, the pattern texture122shown inFIG.5is composed of a plurality of rhombus-shaped points being arranged in parallel, and the pattern texture122shown inFIG.6is composed of a plurality of linear lines being staggeringly arranged to form triangular and trapezoidal shapes, but here is not intended to be limiting. The pattern texture122may be composed of any geometrical shapes, for example points, lines and surfaces, or a combination of the above.