CZ20021737A3 - Woven fabrics particularly useful in the manufacture of user support structures - Google Patents

Abstract

A fabric particularly useful in the manufacture of occupant support structures is described. The fabric is desirably leno woven to have a high degree of openness and such that at least a plurality of the yarn intersections are stabilized from relative motion. The fabric includes elastomeric synthetic yarns in at least one fabric direction. At least some of the points of yarn intersection can be supplementally stabilized from relative motion, such as through the use of bicomponent yarns having a sheath which is melted to secure intersecting yarns together. The fabric is also resistant to ultraviolet irradiation so that it retains its physical properties after accelerated exposure to UV irradiation. The fabric provides good support and ventilation, and is suitable for use as a surface fabric in automotive and seating applications.

Description

Technical field

The invention relates to substantially woven textile structures. In particular, the invention relates to woven textile fabrics having good durability, strength, dimensional stability and ventilation properties, which are particularly adapted for use in the manufacture of user-supported structures for use in the manufacture of user-supported structures such as seating, beds and the like.

BACKGROUND OF THE INVENTION

Traditional user-friendly load-bearing structures such as sofas, beds, etc. they are usually made of a fabric construction attached to some shape of the frame. Usually, user-supporting structures include other load-bearing elements such as springs, cushions, cushions, straps, reinforcing ribs and the like. Such additional support members typically make up a large part of the total weight and dimensions of the user support structure.

Many finished products need to minimize the weight of the overall construction. For example, in the manufacture of vehicles such as automobiles or aircraft, the weight of the overall structure may affect variable variables such as fuel efficiency, cargo load, and the like. Similarly, many supporting structures for home and office use (eg chairs, sofas, etc.) move very often and regularly. In such situations, it is therefore advantageous to minimize the weight of the structure to facilitate its movement. Therefore, in many cases it may be desirable to minimize the weight of the user-supporting structures. However, it is important that they retain the ability to provide the correct support and comfort for their end use.

Another drawback associated with many conventional forms of user-supported structures is that many materials that are commonly used tend to make the user feel cold or hot, depending on certain environmental conditions. E.g. the tendency to feel hot in the car seat is known to anyone sitting on the leather seat of the vehicle in the summer heat. Further, the materials are usually airtight and therefore tend to block airflow along adjacent parts of the user's body. As a result, the back of the seated person's legs can sweat and sitting on a seat made of conventional materials is uncomfortable for a long time.

Further difficulties and costs associated with the system of utility load-bearing structures arise due to the large number of structural elements required for their manufacture. To reduce the complexity of the assembly process, it may in many cases be desirable to produce a user-supported structure using a minimum number of elements. However, the reduction in the number of elements must be balanced to achieve accurate performance.

In many finished products, the materials used to manufacture the user-supporting structures are subjected to many forces that destroy the materials. eg car seats are exposed to a wide range of temperatures, compressive forces, transverse shear forces and the like. Further, such support structures are typically exposed to ultraviolet (UV) radiation and radiation from the vicinity of the ultraviolet portion of the sunlight spectrum that passes through the protective glass and windows. UV radiation tends to undesirably damage many kinds of materials, making them unsuitable for use as surface fabrics in environments where they may be exposed to a high degree of UV radiation. Therefore, with the minimization of elements, the strength and durability of the elements used becomes much more important. Furthermore, manufacturers must normally consider other properties such as contact properties, pattern, style, and the like in order to achieve a proper balance of properties for a particular end use for which the fabric is made.

Materials that have been proposed for use in the manufacture of user-supported structures are described in U.S. Patent Nos. 5,533,789 and 5,596,888 to McLarty et al., And are incorporated herein by reference. U.S. Patent 5,533,789 (McLarty) discloses seating structures having parts made of warp knitted weft insert fabric. The fabric has an elastomeric monofilament in the warp forming the operating side, an elastomeric yarn with a weft yarn in the weft forming an aesthetic surface, and knitting yarn of filaments binding the warp and weft together.

No. 5596888 (Mc Larty) discloses a knitted fabric for furniture having a multi-directional extensibility characteristic and exhibiting sufficient strength and durability to serve as a support in seating or bedding structures. The carrier furniture fabric is a four-rod knitted structure comprising two yarns of decoratively treated polyester and two yarns of elastomeric monofilament intertwined so that the fabric has an elongation at break of at least 17 percent in both the weft and warp directions. Although it exhibits good physical properties for many end uses, it has been found that fabrics made according to Mc Larty patents 5533789 and 5596888 are coarser to the touch than needed for certain end uses.

US Patent No. 4,469,739 to Gretzinger et al. Discloses woven furniture carrier materials made in part of elastomeric monofilaments and in part with a non-elastomeric yarn. The non-elastomeric yarn is used as described in the warp direction of the fabric in a preferred embodiment of the structure. The patent discloses that yarns may be fused together at their intersections, or at other times may be attached to each other at the intersections by selecting a weave pattern that is shaped to secure the yarn in place around the fiber, thereby eliminating the need for gluing or welding elastomers.

As noted above, many textiles used as parts of user-supported structures are exposed to ultraviolet radiation for a relatively long time. E.g. materials for car seats, outdoor chairs, etc. are exposed to UV radiation according to experience. In many cases, UV exposure damages the fibers forming the fabric, thereby undesirably reducing the life of the structure or making certain fabrics unsuitable for certain end products.

An example of a fabric capable of withstanding UV damage is described in U.S. Patent No. 5,856,249 to Waldrop et al., Which is incorporated herein by reference. The Waldrop patent discloses a fabric having a plurality of elastomeric yarns running in a first direction interwoven with a plurality of synthetic yarns running in a second direction substantially transverse to the first direction, wherein the elastomeric yarns running in the first direction constitute no less than about 40 percent by weight of the fabric. The elastomeric yarns running in the first direction are further characterized by the fact that they have an elongation at break of not less than about 50% and maintain no less than about 80% of their tensile strength upon accelerated exposure to up to 488 kilojoules of ultraviolet radiation. The patent discloses that the fabric is preferably a woven fabric, and in particular one that is woven in a structure such as baratea (fine wool or semi-silk fabric). Because of the resistance to UV damage, the fabric can be used as a surface material for car seats.

Further, patent application No. 09/224980 (WALDROP et al.), Pending on January 4, 1999, discloses a fabric usable as an upholstery surface fabric for the automotive industry. This application is incorporated herein by reference. The fabric has a plurality of elastomeric yarns running in the first direction and a plurality of synthetic yarns running in the second direction substantially transverse to the first direction, wherein the elastomeric yarns running in the first direction contain no less than about 40 percent by weight of the upholstery fabric. The elastomeric synthetic yarn running in the first direction has an elongation at break of not less than 70% and is stable when exposed to UV radiation.

SUMMARY OF THE INVENTION

The present invention overcomes the drawbacks associated with conventional structures by providing a fabric having the desired levels of durability, strength, dimensional stability, and elastomeric properties, thereby demonstrating very suitable properties for use in the manufacture of user-supporting structures. The fabric of the invention is pleasant to the touch and retains the desired physical properties even when exposed to ultraviolet radiation for extended periods of time. As a result, it acts well as a surface fabric in user-supporting structures such as car seats and the like. Furthermore, the fabric of the present invention has a high degree of air permeability so that it has good ventilation properties. Because of its unique design, the fabric can be attached to the frame itself (i.e., without additional other textile layers) to form a support structure or can be used in combination with other layers as needed. Further, the fabric can be cut into portions of the desired shape and size and made into an end-use product without undesirable damage to the fabric by unraveling or the like.

· • · · · · · · · · · · · · · · · ·

The fabrics of the invention achieve the desired properties by using elastomeric synthetic yarns in an open woven structure formed by first and second sets of intersecting yarns. The fabric is preferably woven in a leno weave or a variation thereof so that the warp yarns of the fabric are secured around at least some of the feeder fibers. The yarns of the first and second sets are also auxiliary to each other at their intersections as required.

In a preferred embodiment of the invention, the elastomeric synthetic yarns are preferably in the warp and preferably are a two-component, alternate sheath / core. The sheath components preferably have a melting point that is below the melting point of the core component, so that the sheath may be melted subsequent to weaving to secure the yarns of the respective sets at their intersections. The second set of yarns may or may not comprise elastomeric synthetic yarns with yarns, which are preferably selected to form a fabric with some combination of physical properties such as a pleasant touch and aesthetic appearance.

At least some of the yarns forming the fabric are preferably UV-resistant such that the fabric retains at least 50% and more preferably at least 70% of its original tear strength as measured in the direction of the elastomeric synthetic yarn and at least about 50% of its original strength as measured. perpendicular to the direction of the elastomeric synthetic yarn, and after prolonged exposure to 225 kilojoules of UV radiation.

The fabric has high strength and dimensional stability and resists fiberisation. Further, the fabric is also desirably open so that at least about 15%, and more preferably at least about 30% of the area is an open area. More preferably, the open fabric is at least about 35% and more preferably at least about 40% of the area. Indeed, it has been found that fabrics having at least 45% open area can be fabricated according to the present invention while maintaining sufficient strength and dimensional stability to be used in the manufacture of user-supporting structures. Furthermore, products made according to the present invention using UV-resistant yarns are particularly suitable for the manufacture of user-supporting structures that are exposed to UV radiation for extended periods of time, such as automobile seats.

DETAILED DESCRIPTION OF THE INVENTION

In a further detailed description of the invention, certain preferred embodiments of the invention are described in order to allow a complete and comprehensive understanding of the invention. It should be noted that they are not intended to limit the invention to certain preferred embodiments described, and although certain terms are used in the description of the invention, these terms are used in a descriptive sense only for purposes of illustration and not for purposes of limitation.

The fabric of the present invention is designed to provide a high degree of fabric openness. Preferably, about 15% of the surface area of the fabric piece forms an open space (i.e., the space between the fibers or yarns forming the fabric), and more preferably at least about 30%. Even more preferably, at least about 35% of the fabric is open space and even more preferably about 40%. In some embodiments of the invention, it is desirable to have at least 45% of the area of the fabric that forms the open area.

Preferably, the fabric of the invention comprises a first set of yarns extending in a first direction and a second set of yarns extending transversely to the first direction. For example, the fabric is preferably a woven fabric in which one of the first and second sets of yarns is warp yarn and the other of the first and second sets of yarns is a weft (yarn) set of yarns.

• · · · ·

The fabric is woven and comprises a plurality of elastomeric synthetic yarns in at least one of the first and second sets, preferably the warp yarn set. In some embodiments of the invention, the elastomeric synthetic yarns are comprised in both the first and second sets of yarns. In a preferred embodiment of the invention, the elastomeric synthetic yarn is preferably monofilament yarn having an elongation at break of at least about 50% and preferably a tensile strength of at least 3.85 kg (8.5 lbs) of force. Even more preferably, the elastomeric synthetic yarns are monofilament yarns having an elongation at break of at least 75% and even more preferably at least 90% and even more preferably at least 100%.

In a particularly preferred embodiment of the invention, the elastomeric synthetic yarns are of the sheath / core type, wherein the sheath has a lower melting point than the melting point of the sheath portion. In this embodiment of the invention, the melting temperature of the sleeve is preferably at least 14.15 ° C (30 ° F) lower than the core, for reasons to be described in more detail below. Elastomeric synthetic yarns which have been found to be particularly suitable for the invention are distributed under the trade name ELAS-TER® by John Manville of Spartanburg, SC (formerly Hoechst Celanese).

The yarns making up the second set of yarns may be any of a number of materials, depending on the end use of the fabric. For example, in one embodiment of the invention, the second set of yarns also comprises elastomeric synthetic yarns, either alone or in combination with one or many other types of yarns. For example, the filler may comprise other types of elastomeric yarn, polyester, nylon, Teslan natural polyester, elastomer / polyester Teslan yarn combinations, ELAS-TER® polyester wrapped yarns, combinations thereof, or any other type of yarn or combination of yarns having the necessary properties. In most embodiments of the invention, it is usually preferred to include other types of yarns in the second set of yarns (either alone or in combination with an elastomeric synthetic yarn) to achieve a certain functional and aesthetic property of the fabric. For example, in many cases, it will be necessary to use the yarn in a second set of yarns that form a soft-touch fabric or the like. (e.g., using a shaped yarn or spun yarn, and in particular one having a diameter of the total cross section greater than the synthetic yarn, so that it passes out of the fabric to create an aesthetically pleasing surface of the fabric). Alternatively, the second set of yarns may be stripped of elastomeric synthetic yarns, depending on the particular end use for the fabric and the desired physical properties. Further, the single yarn may be inserted in each shed during the weaving process or several yarns may be inserted into one or more shed. It should further be noted that elastomeric yarns may be included in the filler, while other types of yarns are used to form the warp. However, it is preferred to use elastomeric synthetic yarns in at least one warp direction.

In a preferred embodiment of the invention, particularly suitable for producing automotive upholstery, the set of second yarns comprises Taslan polyester yarns of about 600 to 2200 denier. This yarn may be used alone to form a second set of yarns or may be used in combination with an elastomeric synthetic yarn similar to or equal to the yarn of the first set. In such a combination, the elastomeric synthetic yarn component and the other yarn component may be combined prior to weaving (e.g., a forming or twisting process or the like) or the two components may be inserted together during the weaving process without first being combined with each other. Again, a certain arrangement of filling yarns is selected to achieve the desired physical and aesthetic properties.

Preferably, the fabric is woven in a structure wherein at least some warp and feeder yarns are secured to each other by a weave structure rather than by a simple intersection method as with the plain weave structure. Preferably, the bond structure used to stabilize the intersections is a leno-bond structure. (As will be appreciated by those skilled in the art, the leno weave comprises pairs of warp yarns that cross when they surround and secure the filling yarns. The leno weave used herein has a broader meaning and includes all variations of the leno weave). In a preferred embodiment of the invention, all warp yarns are woven in a leno-woven manner, but fabrics having only a portion of warp yarns woven in a leno-woven manner are also within the scope of the present invention. For example, a pattern of alternating leno and linen weaves of woven warp yarn may be used. Alternatively, other weave structures that provide at least some intersections of the yarns against movement relative to one another may be used within the scope of the invention.

Preferably, at least some of the intersections are also additionally secured against relative movement relative to each other. For example, in a preferred embodiment of the present invention, at least a portion of the yarns used to form the woven fabric are thermoplastics so that they can be melted during the heat fixation operation to secure the yarn intersections in the respective first and second sets of yarns against relative movement. In a particularly preferred embodiment of the invention, at least some of the intersections are secured by both the bonding structure used and the further securing.

According to one feature of the invention, at least some of the yarns used to form the fabric are two-component sheath / core yarns having a sheath component with a lower melting point than the core component. Thus, the fabric may be exposed to a temperature higher than the melting point of the sheath (but preferably lower than the melting point of the core component) to melt the sheath and, when the sheath solidifies again, to bind the woven fabric at the intersecting yarns. To this end, it is preferable to use a sheath / core as elastomeric synthetic yarn having a sheath having a melting point at least 14.15 ° C (30 ° F) lower than the core melting point. Due to their uniform structure, the fabrics of the invention can be easily and effectively cut and sewn without unraveling, as is usually the case with known fabrics.

The fabric is also made UV-resistant to retain its strength and other physical properties even after prolonged exposure to UV radiation. In particular, at least some of the yarns, preferably substantially all of the yarns forming the fabric are UV-resistant. In particular, the yarns retain the necessary substantial part of their original tensile strength and elongation characteristics after exposure to high levels of UV radiation for an extended period of time. In a preferred embodiment of the invention, at least one of the first and second sets of yarns comprises elastomeric synthetic yarns that are UV-resistant. In a particularly preferred embodiment of the invention, UV-resistant elastomer yarns are used for the warp yarns of the fabric. Preferably, the UV-resistant elastomeric synthetic yarn retains at least 80%, and more preferably 90% of its original tensile strength after increased exposure to 488 kilojoules of UV radiation in the SAE J 1885 test. In a preferred embodiment of the invention, the UV-resistant elastomeric synthetic yarn maintain at least about 95% of their tensile strength upon prolonged exposure to UV radiation. E.g. a sample of the elastomeric synthetic yarn used to carry out the present invention was tested before weaving, showing a tensile strength of about 4 kp (8.9 lbs) and an elongation at break of about 124% and after prolonged exposure to UV radiation of 488 kilojoules in accordance with the test of The standard of SAE J 1885 showed a tensile strength of 3.21 kp (7.1 lbs) and an elongation at break of about 115%.

As mentioned, the fabrics of the present invention are substantially woven in leno-weave with elastomeric synthetic yarns making up at least 40% by weight. of the total fabric and weave to form a relatively open structure. For example, in a preferred embodiment of the invention, the fabric is woven lined using an elastomeric synthetic yarn of 2250 denier, arranged in a fabric with a binding density of about 0.8 warp threads per cm (20 warp threads per inch). The filler is preferably a polyester yarn having a size of 300 denier or more and which may or may not comprise an elastomeric synthetic yarn component. For example, it has been found that 1650 denier Taslan yarn is suitable for the present invention. It has further been found that the use of 1650 denier Taslan polyester in combination with 400 denier elastomeric synthetic yarn produces a fabric having good physical characteristics. The filler density is preferably about 0.6 to 1.2 wefts per cm (4 to 30 wefts per inch). As noted, several yarns of one or more types may be used in one shed.

Fabrics that essentially use two-component yarns and the sheath / core as elastomeric synthetic yarns are preferably heated to melt the sheath component and secure the first and second yarns at their respective intersections. The yarns are then allowed to cool so that the molten material solidifies again to form a good bond between the yarns of the respective sets of yarns.

The fabrics of the present invention substantially retain at least 50% or more, preferably at least about 70% of their original tear strength as measured in the direction of the elastomeric synthetic yarn and at least 50% of their original tear strength as measured in the second substantially transverse direction after exposure to cumulated radiation of 225 kilojoules according to SAE J 1885. Preferably, the fabric has an elongation at break in the direction of the elastomeric synthetic yarn of at least 70% before and after exposure to elevated levels of UV radiation 225 •

% and preferably at least 70% of its tensile strength in the direction of the elastomeric synthetic yarn after exposure to increased UV radiation. Furthermore, fabrics have a unique combination of strength, durability and dimensional stability as well as aesthetic properties such as a pleasant touch. Furthermore, the fabrics produced according to the invention can be cut and sewn without fraying, thereby making them easier to use in the production of utility support structures than hitherto known fabrics and minimizing waste due to their non-fraying.

Examples

The fabrics were prepared as follows and tested for comparison in the tests below. Each fabric was made on a standard needle loom using a 1752 cm (69 inch) beam width and a 1752 cm (69 inch) warp width. The fabrics were woven as described and the fixation temperature was about 198 ° C (390 ° F) to bind the intersections of the yarn sets.

Sample A was manufactured in a conventional manner to obtain a commercially available product. The fabric was woven in a leno structure to contain oval-shaped elastomeric yarns in the warp and elastomer / polyester Teslan yarns in the filler. None of the yarns used were UV-stabilized and the fabric was not heat-fixed by the method of the present invention.

Sample B was produced according to the present invention. The fabric was formed in a leno weave structure with a warp formed from UV-stabilized ELAS-TER® yarns while the filler contained elastomer / Taslan polyester yarns. The fabric was heat-fixed to melt the sheath of ELAS-TER® yarns and secure the points where the warp intersects with the yarn filling sets.

Sample C was produced according to the present invention. The fabric was fabricated in a leno weave structure using 2250 denier UV stabilized ELAS-TER® yarns in the warp and with two elastomeric / Teslan polyester combination yarns and two natural Taslan polyester yarns were inserted alternately in each shed. In other words, each shed contained a combination of yarn filling one elastomer / Taslan yarn, one natural Taslan yarn, the other elastomer / Taslan yarn, and the other natural Taslan yarn. The fabric was heat-fixed according to the present invention to melt the ELAS-TER® yarns to additionally secure the points where the warp and the yarn filling set intersect.

Sample D was produced according to the present invention. The fabric was formed in a leno weave structure using 2250 denier, UV stabilized ELAS-TER® yarns in the warp and 400 denier ELAS-TER® wrapped with 70 denier polyester yarn in the filler. The fabric was heat-fixed according to the present invention to melt the ELAS-TER® yarns to additionally secure the warp crossing points and the yarn filling sets.

Sample E was produced according to the present invention. The fabric was formed in a leno weave structure using 1000 denier UV stabilized ELAS-TER® yarns in the warp and 400 denier ELASTER® wrapped with 70 denier polyester yarn in the filler. The fabric was heat-fixed in accordance with the present invention to melt the ELAS-TER® yarns and additionally secure the warp crossing points and the feed yarn sets.

The fabric was traveled by the yarn fiber spinning test as described below. The procedure followed closely the burst test described in ASTM D 1117-14 and was conducted as follows: Fabric samples were obtained by cutting a collection of 76.2 x 76.2 cm (3 x 3 inches) sample from each fabric tested. A Sintech tensile tester having upper and lower jaws of 50.8 cm x 76.2 cm (2x3 inches) was used. A measured length of about 19.5 cm (3/4 inches) was used to obtain about 50.8 cm (2 inches) of spinning. The crosshead speed was set to 304.8. cm (12 inches per minute). The sample was first clamped in the lower jaws of the strength tester. One yarn was pulled with a release of about 25.4 cm (one inch) and clamped in the upper jaws of the strength tester. The machine was started and an average of five readings was made (as in the normal procedure of the above break test, so the extreme values were excluded from the program). The fabrics were tested in both the warp and feed directions and the main strength values required to pull the yarns out of the fabric were calculated. The results of the pulping tests are shown in the following table.

Pulping test

Sample average value in warp direction (lb) average value in direction of filler (lb) AND 0 0.189 (B) 8,993 3,811 C 19,418 4,589 D 2,139 1,374 E 0,679 0,634

As mentioned above, a fabric made in the conventional manner (ie, sample A) shows no fiber warp resistance in the warp direction and only a low resistance in the filling direction, i.e. strength (0.189 lb). Conversely, the fabrics produced according to the present invention (i.e., samples B-E) exhibited a significantly higher fibrillation resistance, as evidenced by the substantially higher unraveling forces in each warp and fill direction. Preferably, the fabric produced in accordance with the present invention has a major fiber resistance value at a strength of at least about (5 pounds) in both directions in the warp direction and in the feed direction. Even more preferably, the fabrics have a strength resistance of at least about 2 pounds in the warp direction and at least about 1 pound in the feed direction. Even more preferably, the fabric has a resistance of at least about 8 lbs in the warp direction and at least about 3 lbs in the feed direction. Even more preferred is a fabric having at least 15 lb in the warp direction and at least about 4 pounds) in the feed direction.

Samples A-E were also all subjected to a wire test (following) in both the warp and fill directions, and the average strength was calculated in both directions. A hook-like wire (similar to a fish hook) was hooked behind the fabric to catch about 3-4 strands or wefts of the fabric (depending on the type of fabric being tested and the fabric direction being tested). The force required to cause the hollow fibers to be withdrawn from the fabric was measured and recorded. The test was performed five times in each direction and the average values calculated.

The results are in the following table:

Wire test

Sample Average value in warp direction (lbs) Average value in direction of filling (lbs) AND 0.9 3,014 (B) 81,381 13,451 C 94,248 10,145 D 15,093 4,595 E 4,994 11,247

As can be seen from the above table, the fabrics produced according to the present invention exhibit much greater strength than conventional structures (sample A). Preferably, the fabrics produced according to the present invention have a resistance of at least about 4 pounds in the warp direction and at least about 10 pounds in the feed direction, more preferably having a warp resistance in the warp direction of at least about 15 pounds, even more preferably at least about 36.24 kg (15 pounds) , even more preferably £ 80 and even more preferably at least £ 90. Similarly, the feed direction resistance is required of at least about 10 pounds, more preferably at least about 13 pounds, and even more preferably at least 25 pounds.

Samples A-E were further subjected to the Tear Strength Test as follows: the test piece of fabric was inserted into a groove formed in the side edge of a small metal plate. The groove was about 1/2 inch (about 1.1 cm) deep so that about 1/2 inch (about 1.1 cm) of the fabric () was tucked into the groove. The metal plate comprised first and second apertures having a diameter of about 3/32 inches (0.025 cm) and spaced 1/4 inch (0.635 cm) apart and inwardly 7/16 inch (0.5 cm) apart The metal plate (holding the first and second ends of the fabric) and the free end of the fabric were then pulled apart by a device designed to measure the amount of force required to pull the 7/16 inch (11 cm) edge of the fabric free from the rest of the fabric. was performed five times for each direction, warp direction, and fill direction, and the average values were calculated.

Tear strength test

Sample average value in warp direction (kg) average value in direction of filling (lbs) AND 4,532 12,101 (B) 99.271 66,873 C 44,672 52,995 D 39,993 20,188 E 27,914 28,972

As shown, the fabrics of the present invention have exceptional strength and dimensional stability as compared to prior art fabrics. In fact, it has been found that the excellent dimensional stability and pulping resistance allows the fabric of the present invention to be sheared and handled well in the manufacture of end-use products, which has hitherto been impossible with comparable prior art fabrics.

Samples B, C and D (as described above) were also tested to determine their openness, along with sample F, prepared as follows:

Sample F was produced according to the present invention. The fabric was woven in a leno fabric using UV stabilized ELAS-TER® yarns of 2250 denier in Teslan natural polyester warp and weft and 400 denier ELAS-TER® weft in each shed of filler.

• · · · · · · · · · · · · · · · · · · ·

The fabric was heat-fixed according to the present invention to melt ELAS-TER® yarns to additionally secure the intersections between the warp and the yarn filling sets.

Five areas of each fabric (each area being 45 mm in the warp direction and 60 mm in the filling direction) were measured to determine the percentage of their total area constituting the open area. The results were averaged and recorded below. The number of holes per uniform area of 45 mm x 60 mm was also calculated by computer and the average for each fabric was calculated. The results are shown in the table below:

Openness test - percentage of openings from total area

Sample (B) C D F Area # 1 18.7% 36.9% 44,2% 40% Area # 2 19.3% 37.3% 47,8% 39.6% Area # 3 18% 37.4% 48.9% 41.1% Area # 4 19.7% 39.8% 47.9% 41.2% Area # 5 19.4% 40.1% 48.1% 42.5% Diameter 19.2% 38.3% 47.4% 40.1%

Number of holes per unit area

Sample (B) C D F Area # 1 896 316 488 324 Area # 2 974 312 488 342 Area # 3 953 320 475 334 Area # 4 985 298 482 329 Area # 5 996 309 484 322 Diameter 960.8 311 483.4 330.2

• · r ·

As noted, the disclosed fabrics of the invention have at least about 15% open area, more preferably at least about 30%, and even more preferably at least about 35%, and even more preferably at least about 40%. Further, fabrics having at least about 45% open area can be made, and as shown in sample D, with the necessary strength levels to be used for many different end-use products.

In contrast, a typical fabric with a baratea structure (similar to the fabric described in US Patent No. 5,856,249 described above) would have only about 5% openness, while the fabrics of the present invention achieve substantial openness. As mentioned above, a high percentage of openness increases the comfort of the fabric as well as improves the desired aesthetic appearance. Moreover, despite their high degree of openness, the fabrics have good strength and dimensional stability, as is evident from the fiberizing test and other tests described previously.

Described herein is a preferred embodiment of the invention and although certain terms are used, they are used in a general and descriptive sense only and not for the purpose of limitation, the scope of the invention being set forth in the claims.

Claims (13)

1. A textile fabric characterized in that it comprises: a first set of yarns interwoven with a second set of yarns in a leno configuration, wherein the first set of yarns is secured around the yarns of the second set to form intersections therebetween, wherein the first set of yarns comprises elastomeric synthetic yarns, the yarn sheaths of the first set are melted to provide intersections between the first set of yarns and the second set of yarns. Textile fabric according to claim 1, characterized in that the yarns of the second set of yarns comprise decoratively treated yarns. 3. The textile fabric of claim 1, wherein the yarns of the second set of yarns comprise spun yarns. 4. The textile fabric of claim 1, wherein the yarns of the second set of yarns have an overall cross-sectional diameter greater than that of the yarn of the first set of yarns. 5. The textile fabric of claim 1, wherein the yarn sheath of the first set of yarns has a lower melting point than the core. 6. The textile fabric of claim 1, wherein the yarn of the first set of yarns comprises monofilament yarns. The textile fabric of claim 1, wherein the elastomeric synthetic yarns of the first set of yarns have an elongation at break of at least 50%. ·· »» The textile fabric of claim 1, wherein the elastomeric synthetic fibers of the first set of yarns have an elongation at break of at least 75%. 9. The textile fabric of claim 1, wherein the elastomeric synthetic yarns of the first set of yarns have an elongation at break of at least 90%. The textile fabric of claim 1, the elastomeric synthetic yarn having a first break of at least 100%. characterized in that the sets have elongations at The textile fabric of claim 1, wherein the yarns of the second set of yarns comprise an elastomeric synthetic yarn. 12. The textile fabric of claim 1, wherein the yarns of the second set of yarns comprise elastomeric synthetic yarns and not elastomeric synthetic yarns. The textile fabric of claim 1, wherein the yarns of the second set of yarns comprise polyester.