Composite fabric manufacturing method and composite fabric

Abstract

A composite fabric includes a base fabric structure, a cover structure, and a plurality of ring-shaped composite structures. The base fabric structure has an upper surface, and the cover structure is disposed on the upper surface of the base fabric structure. The ring-shaped composite structures are disposed between the base fabric structure and the cover structure, and the cover structure covers the ring-shaped composite structures. Each ring-shaped composite structure includes an inner through hole for allowing the base fabric structure to be seen through. The ring-shaped composite structures are arranged at intervals, and there is a gap between the ring-shaped composite structures. In this way, the extensibility and the mobility of the composite fabric can be improved without reducing the protection.

Description

Technical Field

[0001] This invention relates to a method for manufacturing composite fabrics and composite fabrics, and more particularly to a method for manufacturing composite fabrics having a ring-shaped composite structure and composite fabrics. Background Technology

[0002] Generally, to protect users, such as athletes during sports collisions, existing composite fabrics typically have an elastic material layer between the two layers to provide protection. However, while providing protection, the elastic material layer reduces the fabric's stretch and mobility, thus decreasing flexibility and causing discomfort during use.

[0003] In response, some manufacturers have developed a new type of composite fabric by punching through holes in the elastic material layer to improve the extensibility of the composite fabric. While this can improve flexibility to some extent, it still hinders mobility when stretched over a large area.

[0004] In view of this, a composite fabric that can provide protection while maintaining flexibility and mobility remains a common goal for relevant industries. Summary of the Invention

[0005] The purpose of this invention is to provide a method for manufacturing composite fabrics and a composite fabric, which uses a die to punch out a ring-shaped composite structure with gaps between the rings, thereby improving the extensibility and mobility of the composite fabric without reducing the protective force.

[0006] According to one embodiment of the present invention, a method for manufacturing composite fabric is provided, which includes a ring-shaped composite structure cutting step. In the ring-shaped composite structure cutting step, a punching die is used to cut a composite substrate to form multiple ring-shaped composite structures. The specific steps are as follows: a first punching is performed, in which multiple inner edge cutters of the punching die are pressed down to form multiple inner through holes in the ring-shaped composite structure; then a second punching is performed, in which multiple outer edge cutters of the punching die are pressed down to form multiple annular gaps to separate the ring-shaped composite structures.

[0007] This allows the first and second punching stages to be completed in a single process, thereby forming a ring-shaped composite structure that is separated from each other, and enabling the subsequent production of a composite fabric that can provide both protection and stretch.

[0008] According to the composite fabric manufacturing method described in the preceding paragraph, the composite substrate may include an elastic material layer, an adhesive layer and a cutting force layer. The elastic material layer is adjacent to the punching die, the cutting force layer is away from the punching die, the adhesive layer is disposed between the elastic material layer and the cutting force layer, and in the second punching step of the annular composite structure cutting step, each outer edge cutter does not cut through the cutting force layer.

[0009] The composite fabric manufacturing method according to the embodiments described above may further include a bonding step. In the bonding step, the annular composite structure is bonded to a base fabric structure and a covering structure, such that the annular composite structure is located between the base fabric structure and the covering structure, thereby completing a composite fabric.

[0010] According to another embodiment of the present invention, a composite fabric is provided, comprising a base fabric structure, a covering structure, and a plurality of annular composite structures. The base fabric structure has an upper surface, and the covering structure is disposed on the upper surface of the base fabric structure. The annular composite structures are disposed between the base fabric structure and the covering structure, and the covering structure covers the annular composite structures. Each annular composite structure includes an internal perforation for viewing the base fabric structure, and the annular composite structures are arranged at intervals with a gap between them.

[0011] In this way, by separating the gaps between the various ring-shaped composite structures, the extensibility and mobility of the composite fabric can be improved while providing protection.

[0012] The composite fabric according to the embodiments described above has a gap of 0.5mm-2.0mm.

[0013] According to the embodiments described above, each annular composite structure may include an inner edge and an outer edge. The inner edge defines an inner perforation. The outer edge is polygonal in shape, and the polygon has three or more sides.

[0014] According to the embodiments described above, the shape of the inner edge of each annular composite structure can correspond to the shape of the outer edge of each annular composite structure. Attached Figure Description

[0015] Figure 1 A top view schematic diagram of a composite fabric according to a first embodiment of the present invention is shown;

[0016] Figure 2 Show according to Figure 1 Side sectional view of the composite fabric of the first embodiment;

[0017] Figure 3 A schematic diagram showing a plurality of ring-shaped composite structures of a composite fabric according to a second embodiment of the present invention is shown;

[0018] Figure 4 A schematic diagram showing a plurality of ring-shaped composite structures of a composite fabric according to a third embodiment of the present invention is shown;

[0019] Figure 5 A schematic diagram showing a plurality of ring-shaped composite structures of a composite fabric according to a fourth embodiment of the present invention is shown;

[0020] Figure 6 A schematic diagram showing a plurality of ring-shaped composite structures of a composite fabric according to a fifth embodiment of the present invention is shown;

[0021] Figure 7 A schematic diagram showing a plurality of ring-shaped composite structures of a composite fabric according to a sixth embodiment of the present invention is shown;

[0022] Figure 8 A schematic diagram showing a plurality of ring-shaped composite structures of a composite fabric according to a seventh embodiment of the present invention is shown;

[0023] Figure 9 A schematic diagram showing a punching die and a composite substrate according to an eighth embodiment of the present invention; and

[0024] Figure 10 A block flowchart of a method for manufacturing a composite fabric according to a ninth embodiment of the present invention is shown.

[0025] Explanation of reference numerals in the attached figures:

[0026] 100: Composite fabric

[0027] 110: Base fabric structure

[0028] 120, 120a, 120b, 120c, 121d, 122d, 121e, 122e, 123e, 121f, 122f, 123f: Ring-shaped composite structure

[0029] 121: Inner penetration hole

[0030] 122: Inner Edge

[0031] 123: Outer edge

[0032] 130: Encapsulation structure

[0033] 200: Punching Die

[0034] 210: First substrate

[0035] 220: Inner edge cutting tool

[0036] 230: Outer edge cutting tool

[0037] 231: Blade

[0038] 232: Reaching the top

[0039] 233: Damping element

[0040] 240: Second substrate

[0041] 250: Material discharge structure

[0042] 300: Composite substrate

[0043] 310: Elastic material layer

[0044] 320: Adhesive layer

[0045] 330: Cutting the stress layer

[0046] S100: Method for manufacturing composite fabrics

[0047] S110: Cutting steps for ring-shaped composite structures

[0048] S120: Combining steps

[0049] d: gap

[0050] h: Breakthrough Height Detailed Implementation

[0051] Embodiments of the present invention will now be described with reference to the accompanying drawings. For clarity, many practical details will be set forth in the following description. However, the reader should understand that these practical details are not intended to limit the invention. That is, in some embodiments of the invention, these practical details are not essential. Furthermore, for the sake of simplicity in the drawings, some conventionally used structures and elements will be shown in a simple schematic manner; and repeated elements may be denoted by the same or similar designations.

[0052] Please refer to Figure 1 and Figure 2 ,in Figure 1 This diagram shows a top view of the composite fabric 100 according to a first embodiment of the present invention. Figure 2 Show according to Figure 1 A side sectional view of a composite fabric 100 according to an embodiment. (See also...) Figure 1 and Figure 2 As shown, the composite fabric 100 includes a base fabric structure 110, a covering structure 130, and a plurality of annular composite structures 120. The base fabric structure 110 has an upper surface, and the covering structure 130 is disposed on the upper surface of the base fabric structure 110. The plurality of annular composite structures 120 are disposed between the base fabric structure 110 and the covering structure 130, and the covering structure 130 covers the annular composite structures 120. Each annular composite structure 120 includes an inner perforation 121 for viewing the base fabric structure 110. The annular composite structures 120 are spaced apart and there is a gap d between each annular composite structure 120, wherein the annular composite structure 120 may include an elastic material layer.

[0053] Through the elasticity of the elastic material layer, the annular composite structure 120 provides protective force to cushion impacts. Furthermore, the structure of the inner perforation 121 and the gaps d between each annular composite structure 120 allow for movement, enabling each annular composite structure 120 to provide independent protection without affecting others, thus avoiding reduced mobility and improving the extensibility and mobility of the composite fabric 100. This provides protection for the user while maintaining flexibility during use.

[0054] Specifically, the base fabric structure 110 and the covering structure 130 can be made of mesh material, which can be elastic mesh, polyurethane (PU) fabric, thermoplastic polyurethane (TPU) fabric or leather. The elastic material layer of the ring-shaped composite structure 120 can be made of foam material, but the present invention is not limited thereto.

[0055] Furthermore, each annular composite structure 120 may include an inner edge 122 and an outer edge 123. The inner edge 122 defines the inner through-hole 121, and the outer edge 123 is generally polygonal in shape, with three or more sides. Moreover, the shape of the inner edge 122 of each annular composite structure 120 may correspond to the shape of the outer edge 123. In the first embodiment, the polygon has six sides, making the overall shape of the annular composite structure 120 generally a regular hexagonal ring. In other embodiments, the shape of the inner edge may not correspond to the shape of the outer edge; for example, the inner edge may be circular, while the outer edge may generally be hexagonal, but the invention is not limited thereto.

[0056] like Figure 1 and Figure 2 As shown, the gap d between each annular composite structure 120 can be 0.5mm-2.0mm. When the gap d is too large, the protective force provided by the annular composite structure 120 will be reduced; when the gap d is too small, the covering structure 130 will have difficulty covering each annular composite structure 120 individually. In the first embodiment, the gap d is 1.0mm. This allows for improved extensibility and mobility of the composite fabric 100 without reducing the protective force.

[0057] Please refer to Figure 3 The diagram illustrates a plurality of annular composite structures 120a of a composite fabric according to a second embodiment of the present invention. The composite fabric of the second embodiment is similar to the composite fabric 100 of the first embodiment, except that the structure of the annular composite structures 120a is slightly different. Specifically, the outer edge of the annular composite structure 120a is a polygon with four sides; more specifically, the outer edge of the annular composite structure 120a is generally rhomboid in shape.

[0058] Please refer to Figure 4 This diagram illustrates a plurality of annular composite structures 120b of a composite fabric according to a third embodiment of the present invention. The composite fabric of the third embodiment is similar to the composite fabric 100 of the first embodiment, except that the structure of the annular composite structures 120b is slightly different. Specifically, the outer edge of the annular composite structure 120b is a polygon with three sides, and more specifically, the outer edge of the annular composite structure 120b is generally an equilateral triangle.

[0059] Please refer to Figure 5 This diagram illustrates a plurality of annular composite structures 120c of a composite fabric according to a fourth embodiment of the present invention. The composite fabric of the fourth embodiment is similar to the composite fabric 100 of the first embodiment, except that the structure of the annular composite structures 120c is slightly different. Specifically, the outer edge of the annular composite structure 120c is a polygon with six sides. More specifically, the outer edge of the annular composite structure 120c is generally hexagonal, and the side lengths of two opposite sides of the hexagon are greater than the side lengths of the other four sides.

[0060] Please refer to Figure 6 This diagram illustrates a plurality of annular composite structures 121d and 122d of a composite fabric according to a fifth embodiment of the present invention. The composite fabric of the fifth embodiment is similar to the composite fabric 100 of the first embodiment, differing only slightly in the structure of the annular composite structures 121d and 122d. Specifically, the outer edges of the annular composite structures 121d and 122d are polygons with four sides; the outer edge of the annular composite structure 121d is generally a parallelogram, and the outer edge of the annular composite structure 122d is generally a rectangle. The annular composite structures 121d are arranged on both sides of the annular composite structure 122d at an angle, such that the annular composite structures 121d and 122d are arranged in a wavy shape.

[0061] Please refer to Figure 7 This diagram illustrates a plurality of annular composite structures 121e, 122e, and 123e of a composite fabric according to a sixth embodiment of the present invention. The composite fabric of the sixth embodiment is similar to the composite fabric 100 of the first embodiment, differing only slightly in the structure of the annular composite structures 121e, 122e, and 123e. Specifically, the outer edges of the annular composite structures 121e and 122e are polygons with four sides, the outer edge of the annular composite structure 123e is a polygon with three sides, the outer edge of the annular composite structure 121e is generally square, the outer edge of the annular composite structure 122e is generally rhomboid, and the outer edge of the annular composite structure 123e is generally equilateral triangle. The annular composite structures 121e, 122e, and 123e are arranged as follows... Figure 7The geometric shape. In other words, for the same composite fabric, the size and shape of the ring-shaped composite structures 121e, 122e, and 123e are different, which can provide visual changes and strength adjustments, but the present invention is not limited thereto.

[0062] Please refer to Figure 8 This diagram illustrates a plurality of annular composite structures 121f, 122f, and 123f of a composite fabric according to a seventh embodiment of the present invention. The composite fabric of the seventh embodiment is similar to the composite fabric 100 of the first embodiment, differing only slightly in the structure of the annular composite structures 121f, 122f, and 123f. Specifically, the outer edge of annular composite structure 121f is a polygon with five sides, the outer edges of annular composite structures 122f and 123f are polygons with four sides, the outer edge of annular composite structure 121f is generally a regular pentagon, the outer edge of annular composite structure 122f is generally a rhombus, and the outer edge of annular composite structure 123f is generally a rhombus of a different size. The annular composite structures 121f, 122f, and 123f are arranged as follows... Figure 8 The geometric shape.

[0063] Please refer to Figure 9 This diagram illustrates a punching die 200 and a composite substrate 300 according to an eighth embodiment of the present invention. The punching die 200 is used to punch out a plurality of annular composite structures on the composite substrate 300, and includes a first substrate 210, a plurality of inner edge cutters 220, a plurality of outer edge cutters 230, and a second substrate 240. It is worth noting that the annular composite structures punched out from the composite substrate 300 can be the annular composite structure 120 of the first embodiment, which will be described below in conjunction with... Figure 1 and Figure 2 Description of the annular composite structure 120 in the first embodiment. Inner edge cutters 220 are disposed below the first substrate 210, and each inner edge cutter 220 is annular. The inner edge cutters 220 are used to punch an inner through-hole 121 of each annular composite structure 120 in the composite substrate 300. Outer edge cutters 230 are movably disposed on the first substrate 210. Each outer edge cutter 230 is annular and located outside each inner edge cutter 220, and the diameter of each outer edge cutter 230 is larger than the diameter of each inner edge cutter 220. A second substrate 240 is located on the first substrate 210 and is used to press against the outer edge cutters 230.

[0064] With the configuration of the inner edge cutter 220 and the outer edge cutter 230, the first substrate 210 first drives the inner edge cutter 220 downward to punch the composite substrate 300 and punch out the inner through hole 121 of the annular composite structure 120. Then, the second substrate 240 moves downward and presses against the outer edge cutter 230 to punch the composite substrate 300 a second time, and the outer edge cutter 230 cuts out the outer edge 123 of the annular composite structure 120. In this way, the punching (punching out the inner through hole 121) and cutting (cutting out the independent annular composite structures 120) actions can be completed simultaneously in a single mold, thereby overcoming the problem that existing punching molds cannot perform secondary processing, and can be used to subsequently produce a composite fabric that provides protection and has extensibility and mobility.

[0065] Specifically, the punching die 200 may further include a discharge structure 250. The discharge structure 250 is disposed between the first substrate 210 and the second substrate 240 and connected to the first substrate 210. When the second substrate 240 moves downward, it presses against the discharge structure 250, causing the first substrate 210 and the inner edge cutting blade 220 to move further downward to discharge the waste material punched from the composite substrate 300. This improves the smoothness of punching and stripping waste.

[0066] Furthermore, each outer edge cutting blade 230 may include a blade body 231, a stop 232, and a damping element 233. The blade body 231 penetrates through the first substrate 210. The stop 232 is connected to the blade body 231 and is located above the first substrate 210. The damping element 233 abuts between the stop 232 and the first substrate 210, wherein the second substrate 240 abuts against the stop 232 after being pressed down. In this way, when the first substrate 210 moves downward and the inner edge cutter 220 cuts the composite substrate 300, the blade 231 of the outer edge cutter 230 is pushed upward when it contacts the composite substrate 300. It may not cut the composite substrate 300 or only cut a portion of it. The first substrate 210 is still limited by the damping element 233. Then, the second substrate 240 presses down against the top 232, driving the outer edge cutter 230 to cut. The damping element 233 buffers the downward speed of the second substrate 240, preventing excessive cutting force from the outer edge cutter 230 during the second cutting, which could break through the composite substrate 300 and damage the overall structure of the annular composite structure 120, reducing production yield. This improves the stability of the outer edge cutter 230 during cutting.

[0067] like Figure 9As shown, there may be a breakage prevention height h between the tip of each outer edge cutter 230 and the tip of each inner edge cutter 220, and the breakage prevention height h is 0.1mm-2.0mm. Furthermore, the composite substrate 300 may include an elastic material layer 310, an adhesive layer 320, and a cutting force-bearing layer 330. The elastic material layer 310 is adjacent to the punching die 200, the cutting force-bearing layer 330 is away from the punching die 200, and the adhesive layer 320 is disposed between the elastic material layer 310 and the cutting force-bearing layer 330. Specifically, the anti-burst height h can be the thickness of the cutting force layer 330 plus a portion of the adhesive layer 320 thickness, allowing the inner edge cutter 220 to penetrate the composite substrate 300 to cut out the inner through hole 121, while the outer edge cutter 230 cuts to the adhesive layer 320 but not to the adhesive layer 320 or the cutting force layer 330 (approximately 30% to 70% of the thickness of the adhesive layer 320). In the eighth embodiment, the anti-burst height h is 0.5 mm, the elastic material layer 310 can be cut to form a ring-shaped composite structure 120, and the adhesive layer 320 and the cutting force layer 330 are made of materials with different densities and different thicknesses. The cutting force layer 330 can be used to buffer and stabilize the cutting force, preventing the outer edge cutter 230 from breaking through the adhesive layer 320.

[0068] Furthermore, each outer edge cutter 230 and each inner edge cutter 220 can punch out annular composite structures 120a, 120b, 120c, 121d, 122d, 121e, 122e, 123e, 121f, 122f, and 123f as in the second to seventh embodiments, and the present invention is not limited thereto.

[0069] Please refer to Figure 10 This diagram illustrates a block flow chart of a composite fabric manufacturing method S100 according to a ninth embodiment of the present invention. In this ninth embodiment, the composite fabric 100 of the first embodiment and the die-cutting mold 200 of the eighth embodiment are described together, but the invention is not limited thereto. The composite fabric manufacturing method S100 includes a ring-shaped composite structure cutting step S110. In the ring-shaped composite structure cutting step S110, a die-cutting mold 200 is used to cut a composite substrate 300 to form a plurality of ring-shaped composite structures 120. A first-stage cutting is performed, pressing down the plurality of inner edge cutters 220 of the die-cutting mold 200 to form a plurality of inner through holes 121 in the ring-shaped composite structure 120. A second-stage cutting is then performed, pressing down the plurality of outer edge cutters 230 of the die-cutting mold 200 to form a plurality of annular gaps d separating each ring-shaped composite structure 120.

[0070] This allows punching and cutting to be completed simultaneously in a single process, overcoming the problem that existing punching technology cannot perform secondary processing, and enabling the subsequent production of a composite fabric 100 that provides protection and has extensibility and mobility.

[0071] Specifically, the composite substrate 300 may include the elastic material layer 310, adhesive layer 320, and cutting force layer 330 of the eighth embodiment, which will not be described in detail here. During the second punching in the annular composite structure cutting step S110, the outer edge cutter 230 does not cut through the cutting force layer 330. The annular composite structures 120 formed by punching can remain connected through the cutting force layer 330, thereby facilitating subsequent processing procedures after punching.

[0072] The composite fabric manufacturing method S100 may further include a bonding step S120. In the bonding step S120, the annular composite structure 120 is bonded to a base fabric structure 110 and a covering structure 130, such that the annular composite structure 120 is located between the base fabric structure 110 and the covering structure 130, thereby completing a composite fabric 100. Specifically, firstly, adhesive is applied to the base fabric structure 110, and the adhesive side is placed on the die-cut composite substrate 300, so that the side of the elastic material layer 310 away from the adhesive layer 320 is bonded to the base fabric structure 110. Then, the cut stress layer 330 connecting each annular composite structure 120 is removed, and then the adhesive layer 320 in the die-cut annular composite structure 120 is bonded to the covering structure 130, thereby completing the composite fabric 100.

[0073] In summary, the present invention provides a method for manufacturing composite fabrics, composite fabrics, and a punching die, which has the following advantages: firstly, by configuring the inner and outer edge cutters of the punching die, punching and cutting processes can be performed simultaneously; and secondly, by using the gaps between the various annular composite structures, the extensibility and mobility of the composite fabric can be improved while providing protection.

[0074] Although the present invention has been disclosed above with reference to embodiments, it is not intended to limit the present invention. Any person skilled in the art can make various changes and modifications without departing from the concept and scope of the present invention. Therefore, the scope of protection of the present invention shall be determined by the claims.

Claims

1. A method for manufacturing composite fabrics, characterized in that, Include: The cutting steps for a ring-shaped composite structure involve using a punching die to cut a composite substrate to form multiple ring-shaped composite structures. The specific steps are as follows: A first stage of punching is performed, in which multiple inner edge cutters of the punching die are pressed down to form multiple inner through holes in the annular composite structures. Then, a second stage of punching is performed, in which multiple outer edge cutters of the punching die are pressed down to form multiple annular gaps to separate the annular composite structures.

2. The method for manufacturing composite fabrics as described in claim 1, characterized in that, The composite substrate includes an elastic material layer, an adhesive layer and a cutting force layer. The elastic material layer is adjacent to the punching die, and the cutting force layer is away from the punching die. The adhesive layer is disposed between the elastic material layer and the cutting force layer. In the second punching step of the annular composite structure cutting process, each of the outer edge cutting blades does not cut through the cutting force layer.

3. The method for manufacturing composite fabrics as described in claim 1, characterized in that, It also includes a bonding step, which combines the annular composite structures with a base fabric structure and a covering structure, such that the annular composite structure is located between the base fabric structure and the covering structure to complete a composite fabric.

4. A composite fabric, characterized in that, Include: A base fabric structure having an upper surface; A covering structure is disposed on the upper surface of the base fabric structure; and Multiple annular composite structures are disposed between the base fabric structure and the covering structure, and the covering structure covers the annular composite structures. Each annular composite structure includes an inner perforation for viewing the base fabric structure. The annular composite structures are spaced apart and have a gap between them.

5. The composite fabric as described in claim 4, characterized in that, The gap is 0.5mm-2.0mm.

6. The composite fabric as described in claim 4, characterized in that, Each of these ring-shaped composite structures includes: An inner edge defines the inner through hole; and An outer edge, the shape of which is a polygon, and the polygon has three or more sides.

7. The composite fabric as described in claim 6, characterized in that, The shape of the inner edge of each annular composite structure corresponds to the shape of the outer edge of each annular composite structure.

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