Method for manufacturing a reinforced fabric for sustitution of vinyl

Abstract

Provided are a reinforced fabric for substitution of vinyl and its manufacturing method which comprises a process (s1)) in which a HDPE and a UV reinforcing agent are mixed and liquefied and processed into a film; a thread manufacture process (s2); an elongation-cooling process (s3); a weaving process (s4); an original tissue recovery process; a LDPE-UV mixing liquid coating process; and a cutting or linking process (s7). The reinforced fabric for substitution of vinyl manufactured through the above described processes has an enhanced resistance with respect to durability and temperature and moisture, so the service life can be prolonged.

Claims

1. A method for manufacturing a reinforced fabric for substitution of vinyl, comprising: (s1) a process for mixing and liquefying HDPE (High Density Polyethylene) and a UV (Ultraviolet Ray) enforcing agent and forming a film; (s2) a thread manufacture process in which the film manufactured in (s1) is forced to pass over a roller equipped with 100 to 3,000 blades and is cut into threads; (s3) an elongation-cooling process in which the elongating and cooling of the threads manufactured in (s2) is performed 3 to 6 times; (s4) a weaving process in which the threads processed through the elongation-cooling process are woven by warps and wefts using a circular loom into a fabric cloth of 25 g/sq. meter to 300 g/sq. meter, and the numbers of warps and wefts per inch (weave count/inch) are 3 to 20, and the thickness of each of the threads can be increased by increasing denier values, and light transmissivity and strength of the fabric cloth can be enhanced by reducing the numbers of the warps and wefts per inch as compared with other fabric cloths with the same weight; (s5) reinforcing process in which either side of the fabric cloth receives a strong tensional force while the fabric cloth passes around a lower side of a reinforcing triangle-shaped structure; (s6) a LDPE (Low Density Polyethylene) agent coating process, wherein either side or one side of the fabric cloth is coated 5 g/sq, meter to 200 g/sq. meter; and (s7) a linking process in which portions of the fabric cloth manufactured in (s6) are precisely melted and inter-bonded using a heat cutter equipped with a high pressure and temperature roller.

2. The method of claim 1, wherein the mixing of the HDPE and the UV reinforcing agent is performed at a weight % ratio of between 80:20 and 99:1 without adding additional materials, and the mixed material is liquefied using a reeling machine and processed into a film.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The present invention will become better understood with reference to the accompanying drawings which are given only by way of illustration and thus are not limitative of the present invention, wherein;

(2) FIG. 1 is a flow chart of a method for manufacturing a reinforced fabric for substitution of vinyl according to the present invention; and

(3) FIG. 2 is a view illustrating a construction of a reinforced fabric for substitution of vinyl according to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

(4) The present invention is directed to a reinforced fabric for substitution of vinyl and its manufacturing method which comprises a process (s1)) in which a HDPE and a UV reinforcing agent are mixed and liquefied and processed into a film; a thread manufacture process (s2); an elongation-cooling process (s3); a weaving process (s4); an original tissue recovery process; a LDPE-UV mixing liquid coating process; and a cutting or linking process (s7). The reinforced fabric for substitution of vinyl manufactured through the above described processes has an enhanced resistance with respect to durability and temperature and moisture, so the service life can be prolonged.

(5) More specifically, the process (s1)) for mixing and liquefying the HDPE and the UV reinforcing agent and processing into a film comprises a step in which a virgin HDPE (High Density Polyethylene) and a UV reinforcing agent are mixed at a weight % ratio of 80 to 99:1 to 20, and the mixed material is liquefied using a reeling machine and processed into a film.

(6) (s2) In the thread manufacture process, the film manufactured in (s1)) is forced to pass over a roller equipped with 100 to 3,000 blades and is cut into pieces each with a width that a user wants.

(7) (s3) In the elongation-cooling process, the threads manufactured in (s2) are repeatedly elongated and cooled 3 to 6 times for thereby enhancing the strength, durability and service life of the threads.

(8) (s4) in the weaving process, the threads processed through the elongation-cooling process are used as warps and wefts and are processed using a circular loom into a fabric cloth of 25 g/sq. meter to 300 g/sq. meter, and the numbers of warps and wefts per inch (weave count/inch) are 3 to 20, and the thickness of the thread can be increased by increasing the denier values, and the light transmissivity and the strength of the product can be enhanced by reducing the numbers of the warps and wefts per inch based on the use and objects of the products.

(9) (s5) In the original tissue recovery process,

(10) in the middle of opening one side of the first woven fabric cloth manufactured with a circular loom in a weaving process (s4), so as to recover the tissue of the folded portion of the fabric cloth to its original shape, the top of the cylindrical woven fabric cloth coming out of the top of the circular loom is cut open with a heat cutter, and is forced to pass past the lower side of the structure of the triangle whose length is longer than the diameter of the cylindrical woven fabric cloth, thus generating a tensional force of pulling the fabric cloth in all directions, so the folded portions of the first woven fabric cloth and warps and wefts can spread flat uniformly, whereby the woven fabric cloth can be recovered in a uniform and flat shape.

(11) (s6) In the LDPE-UV mixed liquid coating process,

(12) on either side of the fabric cloth manufactured through the original tissue recovery process (s5) is coated, in a range of 5 g/sq. meter to 200 g/sq. meter, a mixture mixed with 80 to 90 weight % and 1 to 20 weight % of the UV reinforcing agent or 10 to 50 weight % of the whole weight of the fabric cloth is coated or plated for thereby reinforcing a resistance with respect to the UV and a strength of the fabric cloth.

(13) (s7) In the cutting or linking process,

(14) a corresponding cut portion of the first woven fabric cloth or fabric cloth manufactured through (s3) or (s6) is melted and cut with a heat cutter, thus preventing the collapse of the woven tissues, and it is possible to supply to a customer a fabric cloth or a first woven fabric cloth with a certain size that a user wants, in such a way to use a way of precisely melting and bonding a fabric cloth using a high pressure and temperature roller.

(15) In addition, in a process for mixing and liquefying HDPE and UV and processing into a film (s1), the virgin HDPE and UV reinforcing agent are mixed at a weight % ratio of 80 to 99:1 to 20 into a film, and a first woven fabric cloth of 25 g/sq. meter to 300 g/sq. meter is manufactured with a circular loom using the threads which were manufactured through the reinforced thread manufacture process in which the elongation and cooling are repeatedly performed. The reinforced fabric for substitution of vinyl according to the present invention comprises a first woven cloth the numbers of warps and wefts of which (weave count/inch) are 3 to 20 whose range can be adjusted based on the use and purpose; and a coating layer on either side or one side of which is coated or plated with 5 g/sq. meter to 200 g/sq. meter corresponding to 10 to 50% of the weight of the whole fabric cloth which was manufactured by mixing LDPE and UV reinforcing agent at a weight % ratio of 80 to 90:1 to 20 for thereby enhancing a resistance with respect to UV and the strength of the fabric cloth.

(16) In addition, the present invention is directed to manufacturing a reinforced fabric for substitution of vinyl which comprises a first woven fabric cloth and a coating layer which are manufactured through the (s1)) to (s7).

(17) As the present invention may be embodied in several forms without departing from the spirit or essential characteristics thereof, it should also be understood that the above-described examples are not limited by any of the details of the foregoing description, unless otherwise specified, but rather should be construed broadly within its spirit and scope as defined in the appended claims, and therefore all changes and modifications that fall within the meets and bounds of the claims, or equivalences of such meets and bounds are therefore intended to be embraced by the appended claims.