Method for fabricating a spacer fabric composite, coating machine and composite fabricated by method thereof

A coating machine for forming a mesh film on a mesh substrate, comprising:

• a coating device to make a resin composition become fluid to apply on a mesh substrate to form a coating film on surfaces of the substrate wherein the mesh substrate is a mesh spacer fabric;
• a transfer device to continuously transfer the substrate;
• and
• a hole opening device to form through-holes on the coated substrate to make the coated substrate become air permeable to obtain a spacer fabric composite;
• wherein the resin composition includes at least one polymer, random copolymer or block copolymer selected from the group consisting of the following or combination thereof:
• polyester, polyurethane, polyamide, and polyol and the resin composition has Young's modulus being more than 108 Pa at temperature below the phase transition temperature;
• the mesh spacer fabric comprises a first outer layer, an intermediate spacing layer and a second outer layer, the meshes of the coated mesh substrate have a dimension shrinkage rate being less than 50%;
• and the spacer fabric composite has air permeability being more than 100 cfm (ft3/min) according to ASTM D737 standard.

A spacer fabric composite, comprising a mesh spacer fabric as a substrate and a resin layer formed on the substrate wherein the spacer fabric composite is fabricated by the method including the following steps:

• providing a resin composition wherein the resin composition includes at least one polymer, random copolymer or block copolymer selected from the group consisting of the following or combination thereof:
• polyester, polyurethane, polyamide, and polyol;
• a coating step to use the resin composition to form a coating film on one side or two sides of the substrate by a coating machine to obtain a coated substrate;
• and
• a hole opening step to use a hole opening device to break menisci of films between meshes of the mesh spacer fabric of the coated substrate to obtain a spacer fabric composite;
• wherein the mesh spacer fabric comprises a first outer layer, an intermediate spacing layer and a second outer layer, the meshes of the mesh spacer fabric after coating the resin layer have a dimension shrinkage rate being less than 50%;
• the spacer fabric composite has air permeability being more than 100 cfm (ft3/min) according to ASTM D737 standard;
• and the resin composition has Young's modulus being more than 108 Pa at temperature below the phase transition temperature.