U.S. patent application number 10/886671 was filed with the patent office on 2005-06-30 for fabric membrane texture and manufacturing method thereof.
Invention is credited to Chen, Hung-En, Chen, Shuh-Heng Hank, Tseng, Ching-Hui, Wang, Ching-Nien.
Application Number | 20050142971 10/886671 |
Document ID | / |
Family ID | 34132860 |
Filed Date | 2005-06-30 |
United States Patent
Application |
20050142971 |
Kind Code |
A1 |
Chen, Hung-En ; et
al. |
June 30, 2005 |
Fabric membrane texture and manufacturing method thereof
Abstract
A fabric membrane texture and manufacturing method thereof
explores a texture of fabric membrane comprising of 3D fabric. An
upper and a lower fiber texture layers of the 3D fabric membrane
are stretched to build up an air sandwich through plural middle
connecting fibers. The 3D fabric enables to execute the functions
of anti-bump, thermal insulating, thermal conductivity, air
permeability and elastic strength. Additionally, a polymer membrane
is used to adhere to at least one of the 3D fabric to build up a
better function of shielding, insulating, or the capacity of
ambiance impedance. Besides, this polymer membrane adheres to the
3D fabric using the process of low-pressure fixation that is
applied to the product enables to obtain the better distance of
spacer.
Inventors: |
Chen, Hung-En; (Taipei,
TW) ; Chen, Shuh-Heng Hank; (Taipei, TW) ;
Tseng, Ching-Hui; (Taoyuan City, TW) ; Wang,
Ching-Nien; (Tu-Chen City, TW) |
Correspondence
Address: |
ROSENBERG, KLEIN & LEE
3458 ELLICOTT CENTER DRIVE-SUITE 101
ELLICOTT CITY
MD
21043
US
|
Family ID: |
34132860 |
Appl. No.: |
10/886671 |
Filed: |
July 9, 2004 |
Current U.S.
Class: |
442/205 ;
442/181; 442/203; 442/304; 442/318 |
Current CPC
Class: |
B32B 2307/712 20130101;
Y10T 442/30 20150401; B32B 2037/1238 20130101; B32B 2307/724
20130101; Y10T 442/3179 20150401; Y10T 442/488 20150401; B32B
2307/302 20130101; B32B 5/26 20130101; B32B 37/1207 20130101; D10B
2403/021 20130101; D10B 2403/0112 20130101; Y10T 442/40 20150401;
Y10T 442/3195 20150401; D10B 2505/18 20130101; D04B 21/16 20130101;
B32B 27/12 20130101; B32B 2307/718 20130101; B32B 2307/732
20130101; B32B 37/1027 20130101; B32B 2307/304 20130101 |
Class at
Publication: |
442/205 ;
442/304; 442/318; 442/181; 442/203 |
International
Class: |
D03D 011/00 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 26, 2003 |
TW |
092137198 |
Claims
What is claimed is:
1. A fabric membrane texture comprising: a 3D fabric comprising a
specific distance of a 3D space texture; at least one adhesive
layer positioning on at least one surface of the 3D fabric; and at
least one polymer membrane being jointed with at least one adhesive
layer.
2. The fabric membrane texture with claim 1, wherein the specific
distance of spacer of 3D fabric texture comprising: a lower fiber
texture layer; an upper fiber texture layer; and a specific
distance of spacer, wherein an upper and lower fiber texture layers
of the 3D fabric membrane are stretched to build up a specific
distance of spacer through a plurality of connecting fibers in the
middle layer.
3. The fabric membrane texture with claim 2, wherein a plurality of
connecting fibers are stiffness fibers.
4. The fabric membrane texture with claim 1, wherein the 3D fabric
is a warp-knitted fabric.
5. The fabric membrane texture with claim 1, wherein the 3D fabric
is a plain interval fabric.
6. The fabric membrane texture with claim 1, wherein the 3D fabric
is a honeycomb interval fabric.
7. The fabric membrane texture with claim 1, wherein the adhesive
layer is chosen from one of the group of EVA, PE, PVC or polyester
resin.
8. The fabric membrane texture with claim 1, wherein the polymer
membrane is chosen from one of the group of PTFE, PVC, PP or
PE.
9. A manufacturing method of a fabric membrane, comprising the
steps of: adding an adhesives powder to at least one surface of a
3D fabric and preheating; adhering at least one polymer membrane
onto at least a surface of the 3D fabric using a low-pressure
fixation process; and taking-up the 3D fabric containing the
polymer membrane.
10. The manufacturing method of a fabric membrane with claim 9,
wherein the low-pressure fixation process is a plane-joint
process.
11. The manufacturing method of a fabric membrane with claim 9,
wherein the low-pressure fixation process is a laminating
process.
12. The manufacturing method of a fabric membrane with claim 9,
wherein the low-pressure fixation process is a coating process.
13. The manufacturing method of a fabric membrane with claim 9,
wherein the low-pressure fixation process is an adhesive process.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a fabric membrane texture
and manufacturing method thereof, herein especially comprising a
texture and thereof method of reinforced membrane of 3D fabric
containing spacer. The method of the present invention applies to
outdoor shield or space insulating materials by mainly using the
low-pressure fixation process to build up a space of spacer.
[0003] 2. Description of the Related Art
[0004] A fabric normally employing for outdoor shield, space
insulating materials or related applications, derivatives and
extensions uses is shown in FIG. 1A which illustrates the
distribution of temperature and airflow of monolayer membrane
texture from a prior art. FIG. 1A reveals that the inner
temperature of this shield increased owing to the outdoor sunshine
directly penetrating this monolayer shield 10'. The high
temperature airflow 16' is in the upper part of this shield,
however the inlet of airflow 12' and the outlet of airflow 14' are
on the lower part of the shield which is not able to deliver the
high temperature out through airflow 18'.
[0005] FIG. 1B, schematically diagramed the distribution of
temperature and airflow of bi-layer membranes texture from the
prior art. FIG. 1B states the inner temperature of the shield is
still high although the bi-layer membranes 20' with inner membrane
22' have air as an insulator which insulates the high temperature
airflow 24' in the area of inner membrane 22'. Because the
temperature difference is not so high between high temperature
airflow 26' and 24' and the inlet of airflow 210' and the outlet of
airflow 220' are on the lower part of the shield, the high
temperature is not able to deliver out through airflow 28'. Both
FIG. 2A and 2B schematically diagram the texture of tri-layer
composite membranes and multilayer composite membranes from a prior
art. Referring to FIGS. 2A and 2B, there are tri-layer composite
membrane 30' comprising a lower fabric 32', a plain woven fabric
34' and an upper fabric 36', and multilayer composite membranes 40'
comprising a fabric substrate 42', a surfactant 44' and a texture
of porosity PTFE membrane 46'. However, the consequence presented
that the thickness is increased and the defect of heat directly
penetrating into inner of texture is not improved.
[0006] U.S. Pat. No. 6,319,864 discloses that two different
textures of fabric adhere to a layer of air impermeable and
waterproof polymer membrane to reach the effect of waterproof,
thermal preserving and thermal insulation for tri-layer texture
fabric. U.S. Pat. No. 5,849,395 discloses the polymer membrane
which is affixed to a release thin plate. After a treatment to the
said polymer membrane, the thin plate is removed, and the polymer
membrane becomes into a two-dimensional reticular to obtain the
effect of penetration through the special process. U.S. Pat. No.
4,954,388 discloses the multilayer composite membrane with the
properties of abrasion resistance and tear resistance. A porous
PTFE membrane is used as a material to strengthen the said
multilayer composite membrane property. The polymer is adhered
between PTFE membrane and fabric composite to be employed to
electromagnetics interruption materials; U.S. Pat. No. 5,692,935
discloses that the composite fabric is made of fabric and a heat
sealable film comprising an inner and outer film layer of linear
low density polyethylene and an intermediate film layer of a
polyamide polymer, which provides a barrier against of solids,
liquid and gases.
[0007] The strengthened fabric membrane of two-dimentional fabric,
in the examples of U.S. Pat. Nos. 6,319,864 and 5,849,395, only
reinforces its strengthened texture design of the plain fabric such
as woven fabrics, warp-knitted fabrics, seine fabrics and bonding
fabrics etc. The characteristics of the texture are the change of
strength and toughness on the direction of plane 360 degrees, but
the defect is lack of the effect of impedance and insulation for
the efficiency of light, heat and dynamics on the direction of
thickness. Especially under the circumstances of the impact of
cold-hot environment, the temperature of inner and outer
transmitting fast results in the disappearance of the efficiency of
insulation due to the time factor and it leads to the disadvantages
of high temperature and muggy inside of applications such as
curtains and shields under the sunshine in summer.
[0008] Moreover, the known design of bi-layer membranes is base on
aforesaid the disadvantages of the strengthened membranes of
two-dimentional fabric. One is developed from the fixed gauge of
the texture of bi-layer membranes using two styles of fabric
membranes through the method of fixed gauge sewing. The fixed gauge
requires to be filled in gas and be maintained in order to build up
the spacer on the direction of thickness. The purpose is to employ
the effect of air layer in the space of the direction of thickness
to achieve the high performance of impedance and insulation. The
disadvantages of this method are the subsectional design
requirement for process, space gauge not able to be precisely
controlled, an enormous work, and requiring long time to maintain
the supply of inner air pressure.
[0009] Therefore, providing a novel fabric membrane texture and
manufacturing method thereof for the aforesaid problems can not
only improve the conventional defects of lacking the effect of
impedance and insulation of efficiency of light, heat and dynamics
in the space of the direction of thickness, but also can be
simplified the process. Based on the inventor engaging on the
research and develop and sales experiences for the related products
for many years, the inventor finally proposes a method to improve
the aforementioned problems for fabric membranes texture and its
manufacturing process according to his professional background.
SUMMARY OF THE INVENTION
[0010] It is an object of the present invention to provide a fabric
membrane texture and manufacturing method thereof which employs 3D
texture for a specific distance of spacer to enable particular
functions of anti-bump, thermal insulating, thermal conductivity,
air permeability and elastic strength. The present invention
enhances the efficiency of high lightweight for effectiveness of
the industry.
[0011] It is another object of the present invention to provide a
fabric membrane texture and manufacturing method thereof which of
the 3D texture of fixed gauge of spacer is a fiber texture of
one-piece form that enables the stability of capability to obtain
the best control. At the same time, not only the processing is
shortened, but also the requirements for application maintenance
are reduced. Especially the prop force of plural connecting fibers
in the direction of thickness enables to stably control the space
size and efficiency for spacer, to increase the dynamic
characteristics in the direction of thickness of fabric membranes
and to enhance the capability of dynamic impedance in the plane
direction.
[0012] Another purpose of the present invention is to provide the
fabric membrane texture and manufacturing method thereof to avoid
the crash damage from the high temperature and pressure for the
middle connecting fibers, through a process of low-pressure
fixation, to exploit the size and characteristics of the fixed
spacer.
[0013] In order to perform the aforementioned purposes, efficiency
and characteristics of each, the present invention discloses that
among a texture of fabric membrane comprising of 3D fabric. An
upper layer and lower fiber texture layer of the 3D fabric membrane
are stretched to build up a spacer of the present invention through
plural connecting fibers in the middle layer to execute the
functions of anti-bump, thermal insulating, thermal conductivity,
air permeability and elastic strength. Additionally, a polymer
membrane is used to mount to at least one of the 3D fabric surface
to build up a better function of shielding, insulating, or the
capacity of ambiance impedance. Besides, this polymer membrane
adhering with the 3D fabric using the process of low-pressure
fixation that is applied to the product enables to obtain the
better clearance of spacer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The accompanying drawing is included to provide a further
understanding of the invention, and is incorporated in and
constitutes a part of this specification. The drawing illustrates
an embodiment of the invention and, together with the description,
serves to explain the principles of the invention. In the
drawing,
[0015] FIG. 1A is a schematic view illustrating the temperature and
air flow of monolayer membrane of prior art.
[0016] FIG. 1B is a schematic view illustrating the temperature and
air flow of bi-layer membranes of prior art.
[0017] FIG. 2A is a schematic view illustrating the temperature and
air flow of tri-layer membranes of prior art.
[0018] FIG. 2B is a schematic view illustrating the temperature and
air flow of multi-layer membranes of prior art.
[0019] FIG. 3 is a manufacturing flow chart of the fabric membrane
of the present invention.
[0020] FIG. 4 is a manufacturing block diagram of the fabric
membrane of the present invention.
[0021] FIG. 5 is a schematic diagram of space fabric membrane of
the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] In order to clearly express and explore the feature
characteristics and efficiency of the present invention for the
committee of patent, the preferred embodiment and detailed
description is as below.
[0023] The method of low-pressure fixation can evade the high
temperature and high pressure resulting from the conventional roll
adhesion used in the known art for fabric membranes and eliminate
the crush damage to the middle connecting fibers which causes the
serious impact of the development of size and characteristics of
spacer.
[0024] Refer to FIG. 3 is manufacturing flow chart of space fabric
membrane for the preferred embodiment of the present invention that
illustrates a manufacturing method of a space fabric membrane
texture comprising the steps of:
[0025] Step S10: adding an adhesive powder to at least one surface
of a 3D fabric and preheating;
[0026] Step S12: adhering at least a polymer membrane onto at least
a surface of the 3D fabric using a low-pressure fixation process;
and
[0027] Step S14: taking-up the 3D fabric containing the polymer
membrane.
[0028] Refer to FIG. 4 is a manufacturing block diagram of space
fabric membrane for the preferred embodiment of the present
invention. FIG. 4 expresses that a powder controller 30 spreads an
adhesive such as EVA, PE, PVC or one in the group of polyester
resin on the top of a 3D fabric 20 such as a warp-knitted fabric, a
plain interval fabric or a honeycomb interval fabric, and a
pre-heater 40 preheats the adhesive to a melting status, and then a
polymer membrane 50 is adhered on the top of the 3D fabric 20
through a low-pressure fixation process 60. Finally, the 3D fabric
is taken up by an automatic take-up machine 70. The aforementioned
low-pressure fixation process 60 comprises a plane-joint process, a
laminating process, a coating process or an adhesive process.
[0029] Refer to FIG. 5 is a schematic diagram of space fabric
membrane for the preferred embodiment of the present invention.
FIG. 5 states that a space fabric membrane texture 10 of the
present invention consists of a 3D fabric 12 comprising a 3D space
texture 120 of a specific distance of spacer, an adhesive layer 14
on at least a surface of the 3D fabric 12, and a polymer fabric
membrane 16 adhered to at least an adhesive layer 14. The
aforementioned 3D space texture 120 of a specific distance of
spacer comprises a lower fiber texture layer1240, an upper fiber
texture layer 1220, and a specific distance of spacer 1260 which is
set by bearing and splitting the lower fiber 1240 and upper fiber
1220 texture layers through the plural middle connecting fibers
1262. The polymer membrane is chosen from one of the group of PTFE,
PVC, PP or PE. The texture of the 3D fabric of the present
invention enables the thermal reflectance of sunshine achieving
70%, thermal absorption achieving 15%, and then the heat being only
15% left which is very suitable for the field of weathering
resistance and energy-saving of day-lighting, for example,
requiring the temperature, light and climate controlling for the
place without non-shadow such as green house, child care room,
floriculture, cultivation factory, conference room, warehouse
etc.
[0030] Description of the preferred embodiment is as below:
1 Fabric Fabric Fabric membrane A membrane B membrane C of the
present of the present of the present Normal canvas invention
invention invention Thickness (h) nm 1.54 1.68 8.04 9.22 Thermal
conductivity 47.1 54.5 78.5 73.4 (.lambda. * 10.sup.-3)W .multidot.
m.sup.-1 .multidot. k.sup.-1 Thermal dissipation 0.064 0.121 0.255
0.3113 (a * 10.sup.-6)m.sup.2 .multidot. s.sup.-1 Thermal
absorption 186 156 155 131 (b) W .multidot. m.sup.2 .multidot.
s.sup.-1/2 .multidot. k.sup.-1 Thermal resistance 15.8 30.8 102 126
(r * 10.sup.-3)k .multidot. m.sup.2 .multidot. w.sup.-1 Heat
transfer density 207 5.99 8.89 9.67 ratio (p) Remark: this
thickness includes the thickness of spacer.
[0031] The improved effectiveness of the present invention due to
the increasing interval of fabric membrane in the direction of
thickness expresses as below:
[0032] 1. The thermal conductivity coefficient increases resulting
in the thermal convection increases horizontally.
[0033] 2. Thermal dissipation increases resulting in the
temperature of the environment increase uniformly.
[0034] 3. Thermal absorption reduces resulting in part thermal
absorption reduces.
[0035] 4. Thermal resistance increases resulting in thermal
insulation increases vertically.
[0036] 5. Heat transfer density ratio increases resulting in the
speed of thermal dissipation increases.
[0037] The main art of fabric membrane of the present invention is
a method of design, composition and figuration for composite
materials of fiber texture of permanent inside space and to set up
function of specific capacity and environment impedance. Therefore,
the field of the main art comprises the method of weaving and
processing of fiber design of forming a permanent inside space
texture, carrier design and figuration, surface subtract design,
the manufacturing method of fabric membrane . . . etc. The
characteristics of applications emphasize on the capability of
elastic resistance of dynamics and the impedance of temperature and
light. Employing the forming art of special fiber texture naturally
sets up a necessary function of spacer. The polymer membrane mainly
provides an impedance while the environment condition changes, the
fiber texture provides the characteristics of dynamics and spacer
especially invests better light weight effectiveness besides high
performance of insulation design. A synchrony design method of
one-piece figuration is used in the fiber texture, which precisely
controls the space size and efficiency for spacer besides
simplifying the process. A method of low-pressure fixation is used
in both the polymer membrane and fiber texture to eliminate the
impact of gauge setting of spacer. The 3D fabric replaces the plane
fabric and increases the function of fabric membrane. And the
spacer improves the characteristics of anti-bump, thermal
insulating, thermal conductivity, air permeability and elastic
strength of fabric membrane. The improvement art of low-pressure
fixation can remarkably avoid the high temperature and high
pressure resulting from the conventional roll adhesion of fabric of
the known art and eliminate the crush damage to the middle
connecting fibers.
[0038] Furthermore, the fiber texture of one-piece figuration of
the present invention enables the stability of capability to obtain
the best control. At the same time, not only the processing is
shortened, but also the requirements for application maintenance
are reduced. Especially the prop force of plural connecting fibers
in the direction of thickness enables to stably control the space
size and efficiency for spacer, to increase the dynamic
characteristics in the direction of fabric membranes and to enhance
the capability of dynamic impedance in the plane direction. These
results in the material requirements and processing cost being
reduced and fast manufacturing and the effectiveness of high
lightweight.
[0039] While certain preferred embodiments of the present invention
have been disclosed in detail, it is to be understood that various
modifications may be adopted without departing from the spirit of
the invention or scope of the following claims.
* * * * *