Method of manufacturing functional fabric
10219564 ยท 2019-03-05
Assignee
Inventors
Cpc classification
B33Y10/00
PERFORMING OPERATIONS; TRANSPORTING
A41D7/00
HUMAN NECESSITIES
B29C64/106
PERFORMING OPERATIONS; TRANSPORTING
B29C64/118
PERFORMING OPERATIONS; TRANSPORTING
B29C64/112
PERFORMING OPERATIONS; TRANSPORTING
B33Y80/00
PERFORMING OPERATIONS; TRANSPORTING
B28B1/001
PERFORMING OPERATIONS; TRANSPORTING
B33Y70/10
PERFORMING OPERATIONS; TRANSPORTING
B29K2667/00
PERFORMING OPERATIONS; TRANSPORTING
International classification
B29C41/20
PERFORMING OPERATIONS; TRANSPORTING
B29C64/118
PERFORMING OPERATIONS; TRANSPORTING
B29C64/106
PERFORMING OPERATIONS; TRANSPORTING
A41D13/00
HUMAN NECESSITIES
B29C64/112
PERFORMING OPERATIONS; TRANSPORTING
A41D7/00
HUMAN NECESSITIES
B29C41/22
PERFORMING OPERATIONS; TRANSPORTING
B29C70/68
PERFORMING OPERATIONS; TRANSPORTING
B33Y10/00
PERFORMING OPERATIONS; TRANSPORTING
B33Y70/00
PERFORMING OPERATIONS; TRANSPORTING
B33Y80/00
PERFORMING OPERATIONS; TRANSPORTING
B28B1/00
PERFORMING OPERATIONS; TRANSPORTING
Abstract
The present invention relates to a functional fabric, comprising: a substrate layer, said substrate layer including a cloth and a functional layer on said substrate layer, said functional layer including a silica gel masterbatch and anion additives, and having a three-dimensional configuration, wherein said functional layer has a thickness such that said functional fabric is capable of releasing a concentration of 1,000-6,000 anions per cubic centimeter.
Claims
1. A 3D printing method for manufacturing a functional fabric, comprising the following steps: (a) providing a cloth as a substrate layer of the functional fabric; (b) modeling a functional layer of the functional fabric on computer; (c) providing, melting and mixing a silica gel masterbatch and anion additives, and (d) 3D printing the functional layer on the substrate layer using a 3D printer.
2. The 3D printing method according to claim 1, further comprising the following step: (e) providing one or more additional additives of heat-releasing materials, far-infrared materials, antibacterial materials, aromatic materials and reinforcing materials, the additional additives are melted separately or mixed and melted together with silica gel masterbatch and anion additives, and supplied to the 3D printer.
3. The 3D printing method according to claim 1, further comprising the following step: (f) printing on different locations of the substrate layer a functional layer of varying thickness and/or varying configurations and/or varying components.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The patent or application file contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawing(s) will be provided by the Office upon request and payment of the necessary fee. For better understanding of the present invention, relevant embodiments will be described with reference to the drawings are as follow:
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DETAILED DESCRIPTION OF THE DRAWINGS
(9) Details of the fabric structure and manufacturing method thereof according to the invention will be described as follows. However, the invention does not intend to restrict the structure and method as described. Equivalent alternative methods and equipment that could be conceived by those skilled in the art with reference to the following description of the structure and method are also within the scope of protection of the invention.
(10) Fabric Structure
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(12) One of the main features of functional layer 2 is its three-dimensional structure. Through the three-dimensional structure, the present invention allows the functional layer to have the largest possible volume and surface area/volume ratio. The largest possible volume enables the functional fabric of the present invention to carry far more anion additives than other similar products, and the largest possible surface area/volume enables the anion of the functional fabric of the present invention to be released steadily and effectively.
(13) Firstly, the three-dimensional structure of functional layer 2 indicates a thickness. The thickness allows the functional fabric made by the invention to steadily release a concentration of 1000-6000 anions per cubic centimeters in a static condition, particularly 2000-5000 anions per cubic centimeters and more particularly 3500 anions per cubic centimeters.
(14) Secondly, thickness of the functional layer in the direction perpendicular to the planar surface of the fabric may be even or uneven. As will be discussed below, varying thicknesses can bring different capability of releasing anion and mechanical characteristics to different parts of the clothing, which would be particularly advantageous.
(15) On the other hand, the pattern of the functional layer 2 on the planar surface of the fabric may be regular or irregular. For example, functional layer 2 can have a honeycomb-shaped cross section as shown in
(16) Moreover, the longitudinal section of functional layer 2 can be the same or different. For example, functional layer 2 can have a protruding longitudinal section. The varying longitudinal section can form the functional layer 2 with a hollow porous configuration to further increase the surface area/volume ratio.
(17) Also, functional layer 2 can be continuously applied throughout the substrate layer 1, or applies only to one or more parts of the substrate layer 1.
(18) The three-dimensional structure of functional layer 2 of the functional fabric of the present invention can be changed on all the aforementioned aspects as well as in the other ways which those skilled in the art can reasonably envisage. These changes enable the functional layer 2 to have different and varying three-dimensional structures as needed, which is very helpful to maximize the effect of the anion. From the following section on technical effects, it can be appreciated that the fabric of the present invention has significant effects on reducing muscle injury caused by sport activities and relieve inflammation on parts of the body. Therefore, it is preferred to configure the functional layer 2 in a way such that when people wears the clothes made with that functional fabric 10, the functional layer can concentrate on parts of body most venerable to muscle injury or inflammation, and consequently the concentration of anion released will be the highest there. These parts of body include neck, shoulders, back, waist, thighs, legs and knees. The methods of achieving the concentration of functional layer are as aforementioned, including provides larger thickness on the aforementioned parts, a tighter pattern, a more complex three-dimensional configuration and higher levels of active ingredient.
(19) The fabric so obtained also shows different mechanical properties at different parts. As will be discussed below, the material of the functional layer may have different mechanical properties with the substrate layer, such as higher or lower elasticity and higher wear resistance. Through the uneven and irregular three-dimensional structure of the functional layer, the mechanical properties of the substrate layer may be reinforced purposely. The clothing made by cutting on the basis of the fabric of the present invention may therefore acquire uneven and irregular mechanical properties. For example, the thicker functional layer in the elbows and knees of the clothing can provide higher wear resistance. Also for example, the abdominal region of the functional underwear may provide different components of functional layer to give the fabric a lower elasticity, resulting in better slimming effect. Another example is that in the leg area of sportswear, the functional layer may be provided with higher elasticity so that the fabric has better elasticity.
(20) In other embodiments, the fabric made by the present invention may not be limited to one substrate layer 1 and one functional layer 2. In an embodiment, the fabric of the present invention may comprise two substrate layers 1 and one functional layer 2 therebetween. However, the inventor realizes, it is preferable to expose the functional lawyer. It guarantees high concentration of anion can be effectively released. In another embodiment, the fabric made by the present invention can consist of one substrate layer 1 and two functional layers 2 on the two sides of the substrate layer. It is preferable for application such as sportswear and functional underwear that calls for especially high concentration of anion. The functional layer 2 of the present invention is not limited to the preferred single layer structure.
(21) Fabric Components
(22) The main components of functional layer 2 are silica gel masterbatch and anion additives, further additives such as far-infrared materials, antibacterial materials, aromatic materials and reinforcing materials can be supplemented as needed.
(23) The silica gel masterbatch of the present invention has various micro-porous structures. The micro-porous structures give the silica gel a strong adsorption capacity, which is particularly suitable for maintaining anion additives and other types of additives, and ensuring a stable and lasting release of anion.
(24) Meanwhile, silicone has a stable nature. It is insoluble in water and any solvent. It does not react with any substance except alkali and hydrofluoric acid. It also has excellent flame retardant properties and does not emit smoke or toxic gases even when burning. Therefore, as a masterbatch, the silica gel can protect substrate layer 1 and other components in functional layer 2 so that the fabric of the present invention is suitable for use in a variety of complex weather conditions, and can endure being washed repeatedly in water, high temperature steam cleaning and disinfection without damaging or loss of function.
(25) Silicone also has slow rebound characteristics which gives an excellent elasticity to the functional layer, making it particularly suitable for sportswear.
(26) Anion additives can be in the form of paste or powder, preferably nano-powders. Anion additives may include ZnS, CaO, CePO4, Th(NO3)4 and LaNO3. Other suitable anion additives may also include natural minerals such as tourmaline, opal (aqueous colloidal or amorphous active SiO2 and a small amount of Fe2O3 and Al2O3), tourmaline (inorganic porous substance consisted of silicate, metallic oxide of aluminium and iron) and seabed minerals such as corals fossils, marine sediments and seaweed charcoal.
(27) In a preferred embodiment, the material of the functional layer 2 further includes heat-releasing material. The inventor has found certain level of heat can increase the capacity of the anion additive to release anion. In an experiment conducted by the inventor, two groups of the functional fabric of the present invention are tested, the control group is at room temperature, and the treatment group is heated and maintained at around 28 C. The anion concentrations of the control group and the treatment group are measured after 10, 15 and 20 minutes since heating. Table 2 shows the capability of releasing anion of the functional fabric of the present invention increases by 10-25% after being heated.
(28) TABLE-US-00002 TABLE 2 the effect of temperature on anion concentration Heating Anion concentration/ Anion concentration/ duration/min cm3 Control group cm3 Treatment group 10 2,135 2,339 15 2,054 2,582 20 2,150 2,705
(29) Therefore, the present invention realizes the possibility to add heat-releasing material into the functional layer 2 to improve the anion-releasing capability of the anion additives. In one embodiment, the heat-releasing material is made from conductive nano-particles of composite carbon fiber powder. In a preferred embodiment, the nano-particles of composite carbon fiber powder is made as fluid-like material and formed on insulating polyester film to become a form of nano-heating film, as an independent layer within the functional layer 2. In another preferred embodiment, it is only necessary to mix a concentration of nano-particles of composite carbon fiber powder with the silica gel masterbatch. The heating film made from nano-particles of composite carbon fiber powder has the advantage of very high electricity-heat conversion rate (around 99%, whereas the electricity-heat conversion of a common electric blanket is around 75%), and a power source of 5V, 5 W is sufficient as a stable drive. The surface temperature is even and can reach up to 55 C. However it is preferable to maintain the temperature at 27-29 C. In addition, fabric containing nano-particles of composite carbon fiber powder does not have particular conductive path, it has an area conductive structure. Hence, some damage to the fabric surface will not affect the capability to conduct electricity and to generate heat, as the entire surface is electricity and heat conductive continuously. Besides heat releasing, the nano-particles of composite carbon fiber powder can emit far-infrared light of 8-15 m wavelength when heated, resulting some healthcare function. The ways to energize the fabric includes an USB wire extending from the fabric. There a common portable power bank is sufficient to drive the functional fabric to generate heat.
(30) In a preferred embodiment, the material of functional layer 2 also includes far-infrared materials. The far-infrared materials can radiate far-infrared rays of 3-15 m wavelength at room temperature (20-50 C.), matching human infrared absorption spectrum. Studies show that when far-infrared rays are absorbed by the body, it can make the water molecules in the body resonate and activate, enhance the bonding force between molecules, thereby activating proteins and other biological macromolecules, putting the cell organism at the highest vibration energy level. Since the biological cells produce resonance effect, far-infrared heat can be transferred to the deeper part under the human skin to rise the temperature at the deeper part, the rise of temperature enables the heat to emit from inside out. The effect leads to telangiectasia, promote blood circulation, strengthen metabolism among tissues, increase tissue regeneration, improve immune capacity, regulate the abnormal excited mental state and thus play a role in health care. Suitable far-infrared material includes far-infrared ceramic powder. In an embodiment of the present invention, the far-infrared ceramic powder includes 10-20 wt. % of SiO2, 10-20 wt. % of MnO2, 15-30 wt. % of Al2O3, 4-10 wt. % of CaO, 15-30 wt. % of MgO, 5-20 wt. % mass of Fe2O3, 20-50 wt. % of ZrO2 and 1-5 wt. % of AgCl. In another embodiment, the far-infrared ceramic powder includes SiO2, TiO2, Al2O3, Na2CO2, borax minerals with a small amount of Fe2O3, MnO2, Co2O3 and CuO. Other suitable far-infrared materials include biochar (such as bamboo charcoal powder and bamboo charcoal fiber) and tourmaline.
(31) In another preferred embodiment, the materials of functional layer 2 also include anti-bacterial materials and/or aromatic material. The antibacterial material has the capacity to kill or inhibit microbial. The aromatic material is suitable for perfuming the air continuously.
(32) In another preferred embodiment, the materials of functional layer 2 also include reinforcing material to alter the mechanical characteristics of the fabric. As discussed above, the reinforcing material can be applied unevenly. Embodiment of reinforcing material includes resin and metal wire.
(33) The above-mentioned additional additives can be added by mixing them with silica gel masterbatch.
(34) Manufacturing Method
(35) The functional layer 2 of the present invention has relatively large thickness, making it impossible to apply to the substrate layer 1 with conventional coating methods, such as mechanical coating and impregnation. The use of adhesives between substrate layer 1 and functional layer 2 is also not preferred, because the adhesives layer may fail over time, leading to an undesirable separation of functional layer 2 and substrate layer 1. The inventor has discovered at least two methods to attach functional layer 2 to substrate layer 1. The substrate layer and the thicker functional layer can be firmly bonded together through these methods.
(36) 3D Printing
(37) Traditional 3D printing produces the entire product by using 3D printer. It is hard to be applied to clothing manufacturing. There are very few experimental attempts trying to print the entire garment. It is done by dividing the garment into many small parts, and then the adjacent parts are hinged together. However, the main problem with this type of garment is less flexibility because each part is relatively non-deformable. These widgets are often very thick due to the strength requirement, which further reduces the wearing comfort. The present invention, however, uses a different method. The invention is not making the entire clothes by 3D printing, but prints the functional layer 2 onto the substrate layer 1 by a 3D printer.
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(39) At the beginning of printing, an extrusion pump 8 will input the consumable supplies to the 3D printer 9 from the melting chamber 7. The 3D printer 9 may include single nozzle or multiple nozzles. When driven by motor, the nozzle(s) can move back and forth in three dimensions according to a preset program and carry out 3D printing. At last, carry out surface treatment on the printed functional fabric 10 to make it smooth.
(40) Due to the nature of 3D printing, the present invention can produce a thicker functional layer 2 which cannot be achieved by the existing technology. In addition, the invention also avoids the problem of insufficient elasticity of garment manufactured solely using 3D printing. The present invention prints the functional layer 2 on the substrate layer 1, such that the clothing made from the fabric so manufactured has elasticity between fabric clothing and 3D printing clothing, and close to the fabric clothing. The elasticity of the functional fabric of the present invention ensures comfort in wearing. Lastly, another obvious advantage of 3D printing is easy to control the properties of different parts of the fabric. As aforementioned, the present invention desires to apply different thickness, composition and structure of functional layer 2 on different positions of the substrate layer (i.e., the different positions of the clothing). It is easily achievable by 3D printing technology.
(41) Compression Molding
(42) Another method to apply functional layer 2 of the present invention to substrate layer 1 is compression molding. As shown in
(43) The compression molding method of the present invention allows a relatively thick functional layer 2. The desirable three-dimensional structure, irregular thickness and other structural features of functional layer 2 can be readily achieved by designing the shape of cavity of the mould 19.
(44) In another embodiment, the heat-releasing material can be provided as a separate layer within the functional layer. This is done by producing the conductive nano-particles of composite carbon fiber powder as fluid-like material, and hot press the material onto the polyester film. The so acquired nano heating film is then incorporated onto the functional fabric of the present invention.
(45) Technical Effect
(46) The functional fabric 10 with the structure in accordance with the present invention produced based on the aforementioned method is able to release anion stably under a static condition. With different components and structures, the anion detector COM-3010PRO of Japanese COM SYSTEM, INC. can detect a concentration of 1,000-6,000 anions per cubic centimeter, particularly 2,000-5,000 anions per cubic centimeters and more particularly 3,500 anions per cubic centimeters. The following experiments conducted by the inventor show that wearing the clothing made with the fabric of the present invention can significantly improve health condition.
(47) (1) Experiment with Respect to Muscle Injury Caused by Sports Activity
(48) In the study of muscle injury caused by sports activity, the content of Creatine Kinase is often used as an indirect indicator of muscle injury. Creatine Kinase is also known as Creatine Phospholinase Kinase, it is a kind of enzyme produced by a variety of body tissues that converts the creatine to creatine phosphate with the energy generated by adenosine triphosphate (ATP) converting to adenosine diphosphate (ADP). In the course of strenuous exercise, muscles experience strong contraction, and creatine kinase is released into the bloodstream from muscle tissue, and causes the rupture of membrane of muscle cells. For example, after the completion of marathon, the content of creatine kinase can be as high as 500-3,000 U/I. After, high-strength muscle contraction, the content of creatine kinase can be as high as 25,000 U/I. This kind of severe muscle injury will instantly reduce the muscle strength by 50%, and it takes at least 10 days to fully recover.
(49) The inventor has invited 12 males between the ages of 45 to 65 to participate in the experiment. Among them, 6 are in the control group and the other 6 are in the experiment group. All experiment participants wore mask, carried out 20 minutes exercise on running, cycling and stepping equipments. The only difference was that the control group wore ordinary mask and the experiment group wore mask made by fabric of the present invention which is detected to have an anion concentration of 3,000 per cubic centimeters. Before and after the exercise, venous blood samples were taken from all participants to measure the following data: Number of white blood cell The percentage of lymphocytes Serum creatine kinase (CK) content Serum dehydrogenase (LDH) content Serum lactate (lactate) content
(50) In the first experiment, the inventor compared the group difference of changes of CK, LDH and lactate caused by the exercise. Table 3 shows the measurement results of the average levels of CK, LDH and lactate in the serum of each group 1 hour before and after the 20-minute exercise. It can be sees that before the exercise, the CK, LDH and lactate level of both the control group and experiment group were similar, but differences appeared after the exercise.
(51) TABLE-US-00003 TABLE 3 Average levels of CK, LDH and lactate in the serum of the each group before and after the exercise Before the Exercise After the Exercise Control Group Experiment Group Control Group Experiment Group CK 179.17 67.90 174.33 112.75 195.00 61.67 187.00 120.45 LDH 350.67 84.38 359.17 109.53 435.83 113.61 420.33 114.53 Lactate 3.01 0.56 3.23 0.68 5.92 1.64 4.38 1.23
(52) Table 4 shows the changes of average levels of CK, LDH and lactate in the serum of each group 1 hour before and after the 20-minute exercise. We can see that the increase of CK, LDH and lactate of the experiment group was smaller than that in the control group. In particular, the increase of lactate level of the experiment group was significantly smaller.
(53) TABLE-US-00004 TABLE 4 Changes of CK, LDH and lactate in serum Lactate Group (Number) CK LDH Lactate Control (6) 15.83 13.09 85.17 49.89 2.90 1.69 (+11.25%) (+24.01%) (+100.90%) Experiment (6) 12.67 8.45 61.17 48.57 1.15 0.71 (+7.2%) (+18.12%) (+34.76%)
(54) In another experiment, one participant was selected to conduct the aforementioned 20-minute exercise with ordinary mask and mask made with fabric of the present invention respectively, and the levels of CK, LDH and lactate in the serum was measured 1 hour before and after the 20-minute exercise. As shown in Table 5, the levels of CK, LDH and lactate of the experiment group have smaller increase.
(55) TABLE-US-00005 TABLE 5 Levels of CK, LDH and lactate in the serum before and after the exercise After the Exercise Before the Control Experiment Exercise Group Group CK 116.00 157.00 125.00 LDH 205.00 226.00 224.00 Lactate 2.30 4.80 3.10
(56) The above experiments show that wearing the clothing made by the fabric of the present invention can reduce the muscle injury caused by sports activities to a certain degree.
(57) (2) Inflammation Thermogram Experiment
(58) The inventor also conducted a series of experiments to test the beneficial effects of the fabric of the present invention on alleviating human body inflammation. The inventor have thermogram-imaged the inflammation parts of human body t, and then applied the bandage made from the fabric in accordance with the present invention on the site of inflammation, and observed the changes of the thermogram over time. The red part of the thermogram indicates the hotter parts (i.e. the site of inflammation, also indicated by an arrow in the figures), the deeper the red the more serious inflammation. The green colour represents normal parts.
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(63) The two experiments mentioned above indicate that the functional fabric of the present invention can bring significant improvement to human health by high concentration of anion.
(64) The aforementioned are only part of the embodiments of the invention. Therefore, any equivalent variations or modifications of the structure, features and principles under the scope of the present invention, or any combination of the embodiments of the present invention, are all within the scope of the present invention.