Multilayer mesh structure

Abstract

A multilayer mesh structure has multiple mesh layers being stacked on each other, and may have a woven sheet and a covering layer. Each mesh has multiple primary and secondary fibers. The secondary fibers are mounted crossing over and connecting to the primary fibers at multiple bonded intersections to form the mesh. The woven sheet is formed on a surface of the mesh and may be a natural or man-made fiber (such as rayon, nylon cotton or linen fibers) woven sheet. The covering layer is a film material to enclose and hold the multiple mesh layers. When the multilayer mesh structure is used as a shoe-pad or the like, the multilayer mesh structure provides a shoe with the shoe-pad better air permeability and elasticity.

Description

BACKGROUND OF THE INVENTION

1. Field of Invention

The present invention relates to a mesh, and more particularly to a multilayer mesh structure for upholstery or shoes.

2. Description of the Related Art

Conventional materials for a mattress or a seat pad, such as plastic foam, dry grasses, coconut shell fibers or the like, are either non-breathable or water permeable, they are also prone to mold.

A shoe has a sole and the sole is used to enhance a breathability and elasticity of a shoe. Unfortunately, conventional materials for the sole of a shoe are heavy or water permeable.

The present invention provides a multilayer mesh structure to obviate or mitigate the shortcomings of the conventional materials for upholstery and shoes.

SUMMARY OF THE INVENTION

The primary objective of the present invention is to provide a multilayer mesh structure that is elastic, breathable and covered by a mildew growth-preventing film, suitable for shoes or upholstery.

The multilayer mesh structure has multiple mesh layers being stacked on each other, and may have a woven sheet and a covering layer. Each mesh has multiple primary and secondary fibers. The secondary fibers are mounted crossing over and connecting to the primary fibers at multiple bonded intersections to form the mesh. The woven sheet is formed on a surface of the mesh and may be a natural or man-made fiber (such as rayon, nylon cotton or linen fibers) woven sheet. The covering layer is a film material to enclose and hold the multiple mesh layers.

Other objectives, advantages and novel features of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a multilayer mesh structure in accordance with the present invention;

FIG. 2 is an exploded perspective view of a first embodiment of the multilayer mesh structure in FIG. 1;

FIG. 3 is an enlarged perspective view of a mesh layer in FIG. 1;

FIG. 4 is a perspective view of a second embodiment of the multilayer mesh structure in accordance with the present invention;

FIG. 5 is an exploded perspective view of the multilayer mesh structure in FIG. 4;

FIG. 6 is an enlarged perspective view of a mesh in FIG. 4;

FIG. 7 is a perspective view of a third embodiment of the multilayer mesh structure in accordance with the present invention;

FIG. 8 is an enlarged perspective view of a mesh layer in FIG. 7;

FIG. 9 is a perspective view of a fourth embodiment of the multilayer mesh structure in accordance with the present invention;

FIG. 10 is an exploded perspective view of the multilayer mesh structure in FIG. 9;

FIG. 11 is a perspective view of the multilayer mesh structure with a covering in accordance with the present invention;

FIG. 12 is a perspective view of the multilayer mesh structure with an assistant layer in accordance with the present invention;

FIG. 13 is a cross-sectional view of two enhanced multilayer mesh structures applied on a shoe;

FIG. 14A is an exploded perspective view of one of the enhanced multilayer mesh structures in FIG. 13;

FIG. 14B is an enlarged perspective view of a woven sheet in FIG. 14A;

FIG. 15 is a perspective view of the enhanced multilayer mesh structures in FIG. 14A;

FIG. 16 is an exploded perspective view of the other one of the enhanced multilayer mesh structures in FIG. 13; and

FIG. 17 is a perspective view of the enhanced multilayer mesh structure in FIG. 16.

DETAILED DESCRIPTION OF THE INVENTION

With reference to FIGS. 1, 4, 7, 9, 12, 14A, 15 and 16, a multilayer mesh structure (1, 1A, 1B, 1C, 1D, 1E) in accordance with the present invention comprises multiple mesh layers (10, 10A, 10B), an optional covering layer (20), an optional assistant layer (30), and an optional woven sheet (13).

The mesh layers (10, 10A, 10B) are non-woven, are stacked on top of each other, may be elastic, breathable and have a mildew growth-preventing film, may be thermoplastic elastomer or plastic materials made such as polyethylene (PE), ethylene-vinyl acetate copolymer (EVA), thermoplastic elastomer (TPE) thermal plastic rubber (TPR) or the like. Each mesh layer (10, 10A, 10B) may be bonded to adjacent mesh layers by sewing or adhesion such as thermal adhesion, super sonic adhesion or the like. Each mesh layer (10, 10A, 10B) has two surfaces, multiple primary fibers (11, 11A), multiple secondary fibers (12, 12A) and multiple breathing holes formed between the primary and secondary fibers (11, 11A, 12, 12A). The breathing holes may be uniform in each of the multiple mesh layers (10, 10A, 10B)

The primary fibers (11, 11A) are mounted substantially parallel to each other, are extruded to have at least one regular cross section that may be circular, quadrangular, hexagonal, rectangular or the like and have at least one thickness.

The secondary fibers (12) are mounted substantially parallel with each other, cross the primary fibers (11) at bonded intersections to form the mesh layer (10, 10A, 10B) and are extruded to form at least one regular cross section that may be circular, quadrangular, hexagonal, rectangular or the like and have at least one thickness.

The multiple mesh layers (10, 10A, 10B) are stacked on top of each other to form a multilayer mesh structure (1, 1A, 1B, 1C, 1D, 1E) having two surfaces and two surface mesh layers respectively closest to each surface and at least one middle mesh layer.

With further reference to FIG. 11, the covering layer (20) is a film to enclose the multiple stacked mesh layers (10, 10A, 10B), to allow the multilayer mesh structure (1, 1A, 1B, 1C) to be implemented as upholstery such as a cushion, mattress or the like.

The assistant layer (30) may be a plastic foam, silicon foam or the like, is soft and resilient and is bonded adjacent to at least one multilayer mesh structure (1, 1A, 1B, 1C), and may be bonded between two multilayer mesh structures (1, 1A, 1B, 1C) inside the covering layer (20) to further increase comfort of the upholstery.

With further reference to FIG. 14B, the woven sheet (13) may be natural or man-made fibers (such as rayon, nylon cotton or linen fibers) woven together to form a sheet, and is mounted on one of the surfaces of the multilayer mesh structure (1D, 1E).

With further reference to FIGS. 2, and 3, in a first embodiment of the present invention, the multilayer mesh structure (1) has six stacked mesh layers (10) wherein, the thickness of the primary and secondary fibers (11, 12) of each mesh layer is progressively reduced from one surface mesh layer (10) to the other surface mesh structure (10), so the multiple breathing holes are also progressively reduced from large to small and the primary and secondary fibers (12) are circular in cross-section.

With further reference to FIGS. 5, and 6, in a second embodiment of the present invention, the multilayer mesh structure (1A) has four stacked mesh layers (10A) wherein, the cross-section of the primary fibers (11) and secondary fibers (12) are rectangles.

With reference to FIG. 8, in a third embodiment of the present invention, the multilayer mesh structure (1B) has four mesh layers (10B) wherein, each mesh layer (1B) has alternatively arranged primary fibers (11, 11A) respectively having circular and rectangular cross sections and alternatively arranged secondary fibers (12, 12A) respectively having circular and rectangular cross sections.

With further reference to FIGS. 9 and 10, in a fourth embodiment of the present invention, the multilayer mesh structure (1C) has six mesh layers (10, 10A, 10B), wherein, the cross-section of the primary and secondary fibers (11,12) of one surface mesh layer (10) and the mesh layer (10) adjacent to the surface mesh layer (10) are circles, the cross-sections of the primary and secondary fibers (11,12) of two middle mesh layers (10A) are rectangles, and the other surface mesh layer (10B) and the mesh layer (10B) adjacent to the other surface mesh layer have alternatively arranged primary and secondary fibers (12, 12A) respectively having circular and quadrangular cross sections.

With further reference to FIGS. 13 and 17 the multilayer mesh structure (1D, 1E) may be implemented in a shoe (40). The shoe (40) has an outer upper (41), an inner upper (42), an outsole (43), a sole cushion (44) and innersole (45).

The outer upper (41) corresponds to a foot and has an inner surface and a connecting edge.

The inner upper (42) corresponds to the outer upper (41), is formed on the inner surface of the outer sheet (41), has a connecting edge and comprises the multilayer mesh structure (1D). The multilayer mesh structure (1D) has three stacked mesh layers (10) and one woven sheet (13), wherein breathing holes formed between the primary and secondary fibers (11, 12) of the three mesh layers (10) are progressively decreased in size. The woven sheet (13) is attached to the mesh layer (10) having smaller breathing holes.

The outsole (43) is shaped corresponding to a sole of a foot and attached to the connecting edge of the uppers (41, 42).

The sole cushion (44) corresponds to and is formed on the outsole (43).

The innersole (45) corresponds to and is formed on the sole cushion (44) and comprises the multilayer mesh structure (1E). The multiple mesh structure (1E) has three stacked mesh layers (10) and one woven sheet (13), wherein, the breathing holes formed between the primary and secondary fibers (11, 12) of the three mesh layers (10) are gradually reduced from outside to in. The woven sheet (13) is attached to the mesh (10) having smaller holes between weft and warp than the breathing holes and is larger than the multilayer mesh structure (1E) to cover and hold the multilayer mesh structure (1E) in place.

Even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only. Changes may be made in detail, especially in matters of shape, size and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.

Claims

1. A multilayer mesh structure comprising

multiple mesh layers being non-woven, being stacked on tops of each other and each mesh layer having two surfaces; multiple primary fibers being mounted substantially parallel to each other and extruded to form at least one cross section and at least one thickness; multiple secondary fibers being mounted substantially parallel to each other, crossing the primary fibers at bonded intersections and being extruded to form at least one cross section and at least one thickness; and multiple breathing holes being formed between the primary and secondary fibers.

2. The multilayer mesh structure as claimed in claim 1, wherein the primary fibers and the secondary fibers are circular in cross section.

3. The multilayer mesh structure as claimed in claim 1, wherein the primary fibers and the secondary fibers are rectangular in cross section.

4. The multilayer mesh structure as claimed in claim 1, wherein each mesh layer has alternatively arranged primary fibers respectively having circular and rectangular cross-sections, and alternatively arranged secondary fibers respectively having circular and rectangular cross-sections.

5. The multilayer mesh structure as claimed in claim 1, wherein the multilayer mesh structure further has a covering layer being a film to enclose the multiple mesh layers.

6. The multilayer mesh structure as claimed in claim 1, wherein the multilayer mesh structure further has a woven sheet being formed on one of the surfaces of the multilayer mesh structure.

7. The multilayer mesh structure as claimed in claim 6, wherein the woven sheet is larger than the stacked mesh to cover and hold the multilayer mesh structure.

8. The multilayer mesh structure as claimed in claim 1, wherein the breathing holes of each mesh layer are uniform.

9. The multilayer mesh structure as claimed in claim 1, wherein the breathing holes of each mesh layer progressively decrease in size from one surface of the multilayer mesh structure to the other surface of the multilayer mesh structure.

10. The multilayer mesh structure as claimed in claim 2, wherein the multilayer mesh structure further has a covering layer being a film to enclose the multiple mesh layers.

11. The multilayer mesh structure as claimed in claim 2, wherein the multilayer mesh structure further has a woven sheet being formed on one of the surfaces of the multilayer mesh structure.

12. The multilayer mesh structure as claimed in claim 2, wherein the breathing holes of each mesh layer are uniform.

13. The multilayer mesh structure as claimed in claim 2, wherein the breathing holes of each mesh layer progressively decrease in size from one surface of the multilayer mesh structure to the other surface of the multilayer mesh structure.

14. The multilayer mesh structure as claimed in claim 3, wherein multilayer mesh structure further has a covering layer being a film to enclose the multiple mesh layers.

15. The multilayer mesh structure as claimed in claim 3, wherein the multilayer mesh structure further has a woven sheet being formed on one of the surfaces of the multilayer mesh structure.

16. The multilayer mesh structure as claimed in claim 3, wherein the breathing holes of each mesh layer are uniform.

17. The multilayer mesh structure as claimed in claim 3, wherein the breathing holes of each mesh layer progressively decrease in size from one surface of the multilayer mesh structure to the other surface of the multilayer mesh structure.

18. The multilayer mesh structure as claimed in claim 1, wherein each mesh is elastic, is breathable and is mildew growth preventing.

19. The multilayer mesh structure as claimed in claim 1, wherein each mesh is thermoplastic elastomer or thermoplastic plastic.

20. The multilayer mesh structure as claimed in claim 1, wherein the meshes are bonded to each other by sewing or adhesion.