Patterned Resin Layer Fabrication for Air-Permeable Spacer Fabrics
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Solution Overview
Problem
The existing methods for fabricating spacer fabric composites lack the ability to create a patterned resin layer with air permeability, leading to high production costs and inefficiencies, as they typically coat the entire surface of 3-D fabrics without specific patterning.
Innovation Solution
A method involving film forming, patterning, laminating, and hole opening using a mesh spacer fabric with a resin composition of polymers like polyester, polyurethane, or polyamide, where the resin layer is patterned and laminated onto the fabric, and through-holes are created to achieve air permeability and a specific pattern, utilizing a fabricating machine with devices for film forming, patterning, laminating, and hole opening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a coating method is used to coat a portion of the surface of the 3-D fabric, then the resin layer can be applied to specific areas, but the coating cannot achieve a specific pattern without additional processing steps
Solution Approach 1:
The resin layer is preliminarily formed as a complete film covering the entire 3-D fabric surface, and then the pattern is created by removing resin from specific areas through the hole opening process. This preliminary formation of the complete resin layer enables subsequent precise pattern creation without requiring complex patterned coating equipment.
2Ease of manufacture
If the impregnation method is used, then the whole surface of the 3-D fabric can be coated, but it cannot coat only a portion of the surface with specific patterns
Solution Approach 1:
Instead of attempting to apply resin only to specific areas, the method applies resin to the entire surface and then extracts (removes) the resin from areas where it is not needed through the hole opening process. This extraction approach enables partial coating capability while maintaining the simplicity of full-surface impregnation.
3Adaptability or versatility
If a usual coating method is used, then a portion of the surface can be coated, but the coating lacks specific patterns and requires additional patterning steps
Solution Approach 1:
The method merges the coating process and patterning process into a single integrated operation. By forming the resin layer completely and then creating patterns through hole opening in one continuous process, it eliminates the need for separate coating and patterning steps, thereby improving production efficiency while maintaining partial surface coating capability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces production costs and enhances efficiency while producing a lightweight, air-permeable spacer fabric composite with a patterned resin layer, suitable for various applications, including apparel, shoe materials, and medical care, with improved mechanical properties and environmental friendliness when using polyester.
Implementation Method 1
a film forming step to use a resin composition to form a film wherein the resin composition includes at least one polymer, random copolymer or block copolymer
Implementation Method 2
a hole opening step to use a hole opening device to break menisci of the film between meshes of the mesh spacer fabric
Data Source
AI summary
The invention provides a method for fabricating a spacer fabric composite having a pattern, fabricating machine and composite fabricated by method thereof. The method comprises a film forming step, a patterning step, a laminating step and a hole opening step.