JP2003515011A - Woven fabrics particularly useful for manufacturing 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

Detailed Description of the Invention

TECHNICAL FIELD The present invention relates generally to woven fabric structures. The invention particularly relates to woven fabrics having excellent durability, strength, dimensional stability and breathability which are particularly suitable for use in the manufacture of user support structures such as seats, bedding and the like.

BACKGROUND OF THE INVENTION Typical user support structures, such as seats, bedding, etc., are generally constructed from fabric supports secured to some form of skeleton. User support structures often have additional support elements such as springs, cushions, pads, straps, webs and the like. Such additional support elements generally form a large part of the total weight and size of the user support structure.

In many end uses, it is desirable to minimize the weight of the total structure. For example, in the manufacture of vehicles such as automobiles and airplanes, the weight of the entire structure is
Affects variable factors such as fuel efficiency and fares. Similarly, many home and office user support structures (eg, chairs, sofas, etc.) are often moved frequently. In such situations, it is preferable to minimize the weight of the structure to facilitate its movement. Therefore, it is often required to minimize the weight of the user support structure. However, in their end use it is also important to maintain the ability to provide adequate support and comfort.

Another drawback with many conventional forms of user-supported structures is that many materials commonly used in the manufacture of these structures make them feel cold to the user, depending on the particular environmental conditions. It tends to feel hot or hot. For example, the tendency of car seats to feel hot is readily understandable to those who have sat on car leather seats in the heat of summer. Moreover, the material is generally not breathable and therefore tends to block air flow in areas proximate to the user's body. As a result, after sitting for a long time on a seat made of conventional material, the person sitting on the back feels uncomfortable, sweating on the back of his legs.

Moreover, the problems and costs associated with assembling user-supported structures are generally related to the number of structural elements required to manufacture them. In order to reduce the complexity of the assembly process, it is often preferable to use the minimum number of elements to fabricate the user support structure. However, the reduction in the number of elements must be balanced against the need to achieve a particular performance.

In many end uses, the materials used to manufacture the user support structure are exposed to a variety of degradation forces. For example, automobile seats are exposed to a wide range of temperatures, compressive forces, lateral shear forces, and the like. Moreover, such support structures are generally exposed to ultraviolet (UV) radiation from sunlight through the windshield and windows for extended periods of time. Ultraviolet radiation tends to degrade many types of materials, making them unsuitable for use as surface fabrics in environments exposed to high levels of ultraviolet radiation. Therefore, with the minimization of elements, the strength and durability of the elements used become increasingly important. In addition, the manufacturer also takes into account other properties such as texture, feel, waist strength (drape), etc. to suit the particular end use for which the fabric is manufactured. It must be possible to obtain a balanced characteristic.

Materials proposed for use in the manufacture of user support structures are disclosed in McLarty, III et al., US Pat. Nos. 5,533,789 and 5,596,888, the disclosures of which are incorporated herein by reference. It shall form part of the disclosure. U.S. Pat. No. 5,533,789 to McLarty et al. Discloses a seating structure having a portion made from warp knit fabric with weft insertion. Knitted fabrics have elastomeric monofilament yarns in the warp yarns that perform the performance aspect, elastomeric wrapped filament yarns in the weft yarns that perform the aesthetic aspect, and knitted filament yarns that bind the warp and weft yarns.

US Pat. No. 5,596,888 to McLarty et al. Discloses a furniture-supported knit fabric that is multi-directionally stretchable, has sufficient strength and durability to act as a support in a seat or bed structure. The furniture support fabric is a knitted texture (textur
ed) is a 4-bar knitted structure with two threads of polyester and two threads of elastomeric monofilament, whereby the fabric has an elongation at break of at least 17% in both the warp and weft directions. Have. McLarty et al., U.S. Pat.Nos. 5,533,789 and 5,596,888 may have excellent physical properties for many end uses, yet have a rougher texture than desired for some particular end uses. Was shown.

US Pat. No. 4,469,739 to Gretzinger et al. Discloses a furniture support woven fabric made in part from elastomeric monofilaments and in part from non-elastomeric yarns. In a preferred embodiment of the construction, it is disclosed that the non-elastomeric yarns are fed in the warp direction of the woven fabric. The patent teaches that the yarns can fuse to each other at the intersections or stick to each other at the intersections by choosing a weaving pattern in which the yarns are locked in place around the filament. And thereby obviating the need for adhesive bonding or melting of the elastomer.

As mentioned above, many fabrics used as components in user support structures are exposed to UV radiation for extended periods of time. For example, automobile seat materials, outdoor chairs, etc. are subject to long-term exposure to ultraviolet radiation. Often, exposure to UV radiation degrades the fibers that form the fabric, thereby limiting the useful life of the structure or rendering certain fabrics unsuitable for certain end uses.

An example of a fabric that can withstand degradation by exposure to ultraviolet radiation is disclosed in Waldrop et al., US Pat. No. 5,856,249, the disclosure of which is part of the disclosure of the present invention. And The Waldrop et al. Patent discloses that elastomeric synthetic yarns that run in a first direction are interwoven with synthetic yarns that run in a second direction that is substantially transverse to the first direction to produce an elastomeric composite that runs in a first direction. A woven fabric is disclosed in which the yarn comprises about 40% by weight or more of the woven fabric. Elastomeric yarns running in the first direction exhibit an elongation at break of about 50% or more and about 80% upon accelerated exposure to 488 kilojoules of UV radiation.
It is also characterized by maintaining the above tensile strength. The patent discloses that the fabric is preferably a woven fabric, in particular a woven fabric woven in a Balassian weave structure. Due to its resistance to degradation by exposure to UV radiation, the fabric can be used as a surface material in car seat applications.

In addition, co-pending Waldrop et al. Patent application No. 09/224980 (filed Jan. 1999)
(4th) discloses a fabric which is effective as an upholstery surface fabric for automobiles. The content disclosed in said patent application No. 09/224980 shall form part of the disclosure of the present invention. The fabric has a plurality of elastomeric synthetic yarns that run in a first direction and a plurality of synthetic yarns that run in a second direction that is substantially transverse to the first direction. Make up about 40% by weight or more of upholstered fabric. The elastomeric synthetic yarn running in the first direction exhibits an elongation at break of about 70% or more and is UV stable.

DISCLOSURE OF THE INVENTION The present invention provides a fabric having the requisite levels of durability, strength, dimensional stability, and elasticity, which is particularly suitable for use in the manufacture of user-supported structures. By
The drawbacks associated with conventional structures are overcome. The fabric of the present invention has an excellent hand feel and retains the required physical properties even after prolonged exposure to UV radiation. As a result, it functions well as a surface fabric in user-supported structures such as automobile seats. Furthermore, the fabric of the present invention has a high degree of openness, thereby imparting excellent breathability. Due to its special construction, the fabric can be fixed to the framework by itself (ie, without the use of other fabric layers) to form the support structure, or with other layers if necessary. It can be used in combination. In addition, the dough can be cut to the desired shape and size and can be processed into end-use products without undesired levels of dough degradation, such as raveling.

The fabric of the present invention obtains the desired properties by using an elastomeric synthetic yarn in an open weave structure formed by a first set and a second set of crossed yarns. The fabric is preferably woven in a leno weave or variations thereof, thereby locking the warp threads of the fabric around at least some weft threads. It is also preferable to additionally fix the yarns of the first and second yarn sets at their intersections.

In a preferred form of the invention, the elastomeric synthetic yarns are preferably supplied as warp yarns, preferably bicomponent sheath / core yarns. The sheath component preferably has a lower melting temperature than the core component, so that the sheath can melt after weaving to secure the yarns of each yarn set at their intersections. Other yarn sets may or may not include elastomeric synthetic yarns and the yarns used are preferably selected to give the fabric a particular combination of physical properties such as good hand and aesthetic appearance. .

At least some of the yarns forming the fabric are preferably UV resistant,
Thereby, the fabric maintains an initial breaking strength of at least about 50%, more preferably at least about 70%, as measured in the elastomeric synthetic yarn direction, after accelerated exposure to 225 kilojoules of UV light, and Maintains an initial breaking strength of at least about 50% when measured perpendicular to the elastomeric synthetic yarn direction.

The dough has high strength and dimensional stability and is fray resistant. It is also preferred that the fabric is open, with at least about 15%, and more preferably at least about 30% of the defined area of the fabric being open areas. Even more preferably, the dough has an open area of at least about 35%, more preferably at least about 40%. It has been found in practice that fabrics having an open area of at least 45% can be produced according to the invention while maintaining sufficient strength and dimensional stability for use in the production of user support structures. Furthermore, the products produced according to the invention using UV-resistant yarns are particularly useful for the production of user-supported structures which are exposed to prolonged UV irradiation, such as automobile seats.

In the following detailed description of the invention, certain preferred embodiments of the invention are described in order to provide a thorough understanding of the invention. It is not intended to limit the invention to the particular preferred embodiments described, and specific terminology is used in disclosing the invention, but such term is intended to be exemplary. ,
It should be understood that it is not limiting.

The fabric of the present invention is configured to provide a high degree of fabric openness. Preferably, at least about 15%, and more preferably at least about 30% of the surface area of the fabric constitutes open spaces (ie the spaces between the fibers or threads forming the fabric). More preferably, at least about 35% of the dough is open space, more preferably about 40%. In some embodiments of the invention, at least about 45 of the dough area.
% Preferably constitutes the open area.

The fabric of the present invention preferably has a first set of yarns extending in a first direction and a second set of yarns extending in a second direction, which is substantially transverse to the first direction. For example, the fabric is a woven fabric in which one of the first yarn set and the second yarn set is a warp yarn set, and the other of the first yarn set and the second yarn set is a weft yarn (that is, a twisted yarn in the transverse direction). Is preferred.

The fabric is in at least one of the first and second yarn sets, preferably in the warp yarn set,
Woven to include a plurality of elastomeric synthetic threads. In some embodiments of the invention, both the first and second yarn sets include elastomeric synthetic yarns. In a preferred form of the invention, the elastomeric synthetic yarn has an elongation at break of at least about 50%, preferably a tensile strength of at least about 8 pounds force before weaving, more preferably at least about 8.5 pounds force. It is preferably a monofilament thread. The elastomeric synthetic yarn is at least about 75%, more preferably at least about 90%.
More preferably, it is a monofilament yarn having an elongation at break of more preferably at least about 100%.

In a particularly preferred form of the invention, the elastomeric synthetic yarn is a sheath / core-like yarn and the sheath has a lower melting temperature than the core component. In this form of the invention, the melting temperature of the sheath is preferably at least about 30 ° F below the melting temperature of the core, the reason for which will be explained in more detail below. An elastomeric synthetic yarn that has been found to work particularly well in the present invention is commercially available from Johns Manville (Spartanburg, South Carolina) (formerly Hoechst Celanese) under the tradename ELAS-TER®. .

The yarns forming the second yarn set may be of any material, depending on the intended end use of the fabric. For example, in one form of the invention, the second yarn set also comprises elastomeric synthetic yarns, alone or in combination with one or more other types of yarns. For example, the weft threads impart other types of elastomeric threads, polyester, nylon, natural Taslan polyester, elastomer / Taslan polyester thread combinations, polyester-coated ELAS-TER® threads, combinations thereof, or desired final properties. Other types of threads or thread combinations may be included. In most forms of the invention, it is desirable to include other types of yarn in the second yarn set (alone or in combination with the elastomeric synthetic yarn component) to impart specific functional and aesthetic properties to the fabric. Generally preferred. For example, in many cases, it is preferable to use a yarn for imparting a soft feel to the fabric in the second yarn set (for example, a crimped bulk yarn (textured yarn).
) Or spun yarns, in particular yarns having a larger overall cross-sectional diameter than the elastomeric synthetic yarns, whereby the yarns extend outwardly from the fabric and form an aesthetically pleasing fabric surface). Alternatively, depending on the particular end use intended, the second yarn set may be free of elastomeric synthetic yarns in order to obtain the desired textile and physical properties. In addition, one thread is used for each shed during the weaving process.
, Or multiple threads can be inserted into one or more sheds. Furthermore, it should be noted that other types of yarns may be used to form warp yarns while the elastomeric yarns are fed into the weft yarns. However, it is preferred to feed the elastomer synthetic yarn at least in the warp direction.

In a preferred form of the invention that is particularly useful for making automotive upholstery, the second yarn set comprises Taslan polyester yarn of a size of about 600 to 2200 denier. This yarn can be used alone to form the second yarn set or can be used in combination with an elastomeric synthetic yarn similar or the same as the yarn used for the first yarn set. In such combinations, the elastomeric synthetic thread component and other thread components can also be combined prior to weaving (eg, by texturing or twisting methods, etc.),
Alternatively, the two components may not be combined first and may be inserted together during the weaving process. A particular arrangement of weft threads can also be selected to obtain the desired physical and aesthetic properties.

It is preferred that the fabric be woven into a structure in which at least some of the warp and weft threads are locked together by the weaving structure, rather than merely intersecting as in a plain weave structure. The weave structure used to stabilize the intersections is preferably a leno weave structure or a variation of the leno weave structure (as will be appreciated by those skilled in the art, leno weaves are intended to surround and secure weft threads). The term "entanglement", as used herein, has a broad meaning and is meant to encompass all variations of leno weave). In a preferred embodiment of the present invention, all warp yarns are entangled, but a fabric in which only a part of the warp yarns is entangled is also included in the present invention. For example, a pattern of alternating warp and plain weave warp threads can be used. Alternatively, other woven structures that secure at least some of the yarn intersections against relative movement can also be used in the present invention.

It is also preferred that at least some of the intersections are complementarily fixed so that they do not move relative to each other. For example, in a preferred form of the invention, at least a portion of the yarns used to make up the woven fabric are thermoplastic so that they melt during the heat setting operation to form the first and second yarns. Each of the yarn sets can be fixed so that they do not move relative to each other. In a particularly preferred form of the invention, at least some of the intersections are anchored by both the particular weave construction used and the complementary anchoring.

In one aspect of the invention, at least some of the yarns used to form the dough are sheath / core bicomponent yarns, where the sheath component has a lower melting temperature than the core component. In this way, when the dough is exposed to a temperature above the melting temperature of the sheath (but preferably below the melting temperature of the core), the sheath is melted and when the sheath resolidifies The woven fabric can be bonded at.
For this purpose, a sheath / core yarn having a sheath with a melting temperature at least about 30 ° F below the core is preferably used as the elastomeric synthetic yarn. Due to its special construction, the fabric of the present invention does not suffer from the fraying commonly encountered in prior art fabrics and can be cut and sewn easily and efficiently.

The fabric is also designed to be resistant to UV irradiation, so that strength and other physical properties can be maintained even after prolonged exposure to UV irradiation. In particular, at least some of the threads forming the fabric, and preferably substantially all of the threads, are resistant to UV radiation. In particular, the yarn preferably maintains a substantial proportion of its original tensile strength and elongation properties after being exposed to high levels of UV radiation for extended periods of time. In a preferred form of the invention, at least one of the first and second yarn sets comprises UV resistant elastomeric synthetic yarns. In a particularly preferred form of the invention, a UV resistant elastomeric synthetic yarn is used to form the warp of the fabric. The UV resistant elastomeric synthetic yarn preferably maintains at least about 80%, and more preferably at least about 90% of its original tensile strength after accelerated exposure to 488 kilojoules of UV light according to SAE Test Standard J1885. In a particularly preferred form of the invention, the UV resistant elastomeric synthetic yarn maintains at least about 95% of its tensile strength after accelerated exposure to UV radiation. For example, a sample of elastomeric synthetic yarns useful in practicing the present invention, when tested prior to weaving, exhibits a tensile strength of about 8.9 pounds force and an elongation at break of about 124%, according to SAE Test Standard J1885. After accelerated exposure to kilojoules of UV radiation, it exhibited a tensile strength of 7.1 pounds force and an elongation at break of about 115%.

As noted above, it is preferred to weave the fabric of the present invention in a leno weave in which the elastomeric synthetic threads make up at least about 40% by weight of the total fabric to produce a relatively open construction. For example, in a preferred embodiment of the invention, the fabric is entangled using 2250 denier elastomeric monofilament polyester which is placed in the fabric at a weave density of about 20 ends / inch. The weft threads are preferably polyester threads of 300 denier or thicker and may or may not include an elastomeric synthetic thread component. For example, 1650 denier Taslan yarn has been found to work well in the present invention. In addition, the use of 1650 denier Taslan polyester in combination with 400 denier elastomeric synthetic yarns has also been found to result in fabrics with excellent physical properties. The density of the weft thread is about 4 (picks
) / Inch to about 30 / inch. As mentioned above, it is also possible to feed one or more weft yarns into one shed.

Preferably, a fabric having a sheath / core bicomponent yarn as an elastomer synthetic yarn is
It is preferable to heat-treat to melt the sheath component and fix the first and second yarn sets at their respective yarn intersections. The yarns are then cooled and the molten material is resolidified to form a good bond of the yarns in each yarn set.

The fabric produced according to the present invention has at least about 50%, more preferably at least about 70%, as measured in the elastomer synthetic yarn direction, after being exposed to a cumulative irradiation of 225 kilojoules according to SAE standard J1885. It is preferred to maintain the initial break strength and to maintain an initial break strength of at least about 50% when measured in a generally transverse direction.
The fabric exhibits an elongation at break of at least about 70% before and after exposure to high levels of 225 kilojoules of UV radiation, and after accelerated exposure to UV radiation of at least about 50%, more preferably in the elastomer synthetic yarn direction. Preferably maintains a tensile strength of at least about 70%. In addition, the fabric also has a special combination of favorable aesthetic properties such as strength, durability, and dimensional stability, and hand. Further, the fabric of the present invention can be cut and sewn without fraying, is easier to use in the manufacture of user support structures as compared to prior art fabrics, and Minimize waste.

(Example) A fabric was manufactured as follows, and a comparative test was conducted by the test described below.
Each fabric was made on a conventional rapier weaving machine using a 69 inch reed width and a 69 inch beam width. Fabrics were woven by each method described and heat set at about 390 ° F. to join the intersections of the braids.

Sample A, which is similar to the commercial product, was prepared in a conventional manner. The fabric was woven into a entangled structure such that the oval elastomeric yarn was included in the warp and the elastomer / Taslan polyester yarn was included in the weft. None of the yarns used were UV stable and the fabric was not heat set by the method of this invention.

Sample B was made according to the present invention. Warp thread is 1000 denier UV stabilized ELA
The fabric was formed into a entangled weave structure such that it was formed from S-TER® yarns and the weft yarns included elastomer / Taslan polyester yarns. Heat-fix the dough, ELAS-TER
The sheath of (registered trademark) yarn was melted and the intersection of the warp set and the weft set was fixed.

Sample C was made by the method of the present invention. Using 2250 denier UV-stabilized ELAS-TER® yarns as warp yarns, insert two elastomer / Taslan polyester combination yarns and two natural Taslan polyester yarns alternately into each shed to entangle the fabric Formed into a woven structure. In other words, each shed included a combination of one elastomer / Taslan yarn, one natural Taslan yarn, a second elastomer / Taslan yarn, and a second natural Taslan yarn weft yarn. The fabric was heat set according to the present invention to melt the ELAS-TER® yarn, thereby additionally fixing the intersection of the warp and weft sets.

Sample D was made by the method of the present invention. Tentatively weave the fabric using 2250 denier UV-stabilized ELAS-TER® yarns for the warp and 400 denier ELAS-TER® yarn coated with 70 denier polyester yarn for the weft Formed. The fabric was heat set according to the present invention to melt the ELAS-TER® yarn, thereby additionally fixing the intersection of the warp and weft sets.

Sample E was made by the method of the present invention. Tentatively weave the fabric using 1000 denier UV-stabilized ELAS-TER® threads for the warp and 400 denier ELAS-TER® threads coated with 70 denier polyester thread for the weft Formed. The fabric was heat-set according to the invention to melt the ELAS-TER® yarns and to additionally fix the intersections of the warp and weft sets.

The fabric was tested by the Yarn Unravel Test described below. The procedure is based on the Trap Tear Tes test described in ASTM D1117-14.
The procedure is similar to that of t) and was performed as follows. Dough samples were obtained by cutting 3 inch x 3 inch small pieces (swatches) of each dough to be tested. About 2
A Sintech Tensile Tester with 2 ″ × 3 ″ upper and lower jaws was used to obtain inch unraveling. A gauge length of about 3/4 inch was used. The crosshead speed was set at 12 inches / minute. The sample was first clamped to the lower jaw of the tensile tester. One thread was pulled out 1 inch and clamped in the upper jaw of the tensile tester. The tester was started and the five high nominal values (the extremum was eliminated by the program because of the general procedure used for the trap tear test above) were averaged. Testing the fabric in both the warp and weft directions,
The average pound strength required to pull the thread out of the fabric was calculated. The results of the thread fraying test are shown in the table below.

[0039]

[Table 1] Fray test

As mentioned above, the dough produced by the conventional method (that is, sample A) basically shows no fray resistance in the warp direction and a slight fray resistance in the weft direction, that is, 0.
It only shows 189 pounds strength. In contrast, the fabrics produced according to the present invention (i.e., Samples B-E) had a significant amount of warp and weft direction, respectively, as indicated by the fairly strong force required to fray the thread. Shows high yarn fray resistance. Fabrics made in accordance with the present invention preferably exhibit an average value of fray resistance of at least about 0.5 pound strength in each of the warp and weft directions. More preferably, the fabric exhibits a ravel resistance of at least about 2 pounds in the warp direction and at least about 1 pound in the cross direction. It is further preferred that the dough exhibit a fray resistance of at least about 8 pounds in the warp direction and at least about 3 pounds in the cross direction. It is further preferred that the dough exhibit a fray resistance of at least about 15 pounds in the warp direction and at least about 4 pounds in the cross direction.

Each sample AE was also subjected to a wire test (shown below) in both the warp and weft directions and the average strength in each direction was calculated. Hook a wire with a key (similar to a hook) to the fabric and pick approximately 3-4 ends or picks of the fabric.
s) (depending on the type of fabric tested and the orientation of the fabric tested). The force required to pull the caught thread from the fabric was measured and recorded. The test was performed 5 times in each direction and the average value was calculated. The results are shown in the table below.

[0042]

[Table 2] Wire test

As shown in the above table, the dough produced according to the present invention showed significantly higher strength than the dough of conventional structure (Sample A). Fabrics made in accordance with the present invention exhibit a resistance of at least about 4 pounds in warp threads and at least about 10 pounds in weft threads, more preferably at least about 15 pounds, more preferably at least about 80 pounds, and even more preferably at least about 90 pounds. It preferably has a warp resistance of pounds. Similarly, the weft thread resistance is preferably at least about 10 pounds, more preferably at least about 13 pounds, and even more preferably at least about 25 pounds.

Samples A-E were also subjected to a skewer / tear test as follows. A sample of the fabric to be tested was inserted into a slot formed in the side edge of a small metal plate. The depth of the slot was about 1/2 inch (about 1.1 cm) so that about 1/2 inch (about 1.1 cm) of the fabric edge entered the slot. The metal plate has a diameter of about 3
/ 32 inch (about 0.025 cm) with a first opening and a second opening, which are about 1 to each other.
/ 4 inch (approx. 0.065 cm) interval, and about 7/16 inch (
About 0.5 cm), so that the opening overlapped the slot formed in the side of the metal plate. A handle having a first protrusion and a second protrusion (prong) extending outward from the handle was prepared, and the protrusion was separated by the same distance as the opening of the metal plate. After inserting the edge of the dough into the slot, the protrusion is inserted through the opening (extending over the entire dimension of the metal plate), thereby allowing about 7/16 inch (about 0.5 cm) inward from that edge in the slot. Effectively skewered the dough in position. next,
A metal plate (holding the first end of the fabric) by a machine designed to measure the amount of force needed to pull the 7/16 inch edge of the fabric out of the rest of the fabric structure. And the free end of the dough was pulled apart. The test was conducted 5 times in each of the warp and weft directions, and the average value of the warp and weft was calculated.

[0045]

[Table 3] Skew / tear test

As shown, the fabric of the present invention has superior strength and dimensional stability as compared to prior art fabrics. In fact, due to its excellent dimensional stability and resistance to fraying, it has been found that the fabrics of the invention can be cut and processed during the manufacture of end-use products, which is not possible with comparable prior art fabrics. This is a feature that has been impossible until now.

Samples B, C and D (above) were also tested along with Sample F, prepared as described below, to determine their “openness”.

Sample F was made according to the present invention. 2250 denier UV stabilized ELA on warp
The fabric was woven into a entangled structure using S-TER® yarn and one natural Taslan polyester and one 400 denier ELAS-TER® for each shed of weft yarns. The fabric was heat-set according to the invention to melt the ELAS-TER® yarn, thereby additionally fixing the intersection of the warp and weft sets.

Five areas of each fabric (each area was 45 mm in the warp direction and 60 mm in the weft direction)
Was measured to determine the percentage of open area to total area. The results were then averaged and recorded. The number of openings per unit area of 45 mm × 60 mm was also counted by the computer, and the average of each fabric was calculated. The results are shown in the table below.

[0050]

Table 4 Openness test-percentage of open area to total area

[0051]

[Table 5] Number of openings per unit area

As indicated, the inventive fabrics described above have an open area of at least about 15%, more preferably at least about 30%, even more preferably at least about 35%, and even more preferably at least about 40%. In addition, fabrics having an open area of at least about 45% can also be produced, with favorable strength levels that can be used in a variety of end use products, as shown by Sample D.

In contrast, a typical barasa fabric (similar to the fabric described in the above-mentioned US Pat. No. 5,856,249) has about 5 compared to the outstanding openness obtained with the fabric of the present invention. It only has a% openness. As mentioned above, such a high degree of openness enhances the comfort of the fabric and gives it a pleasing aesthetic appearance. Moreover, despite the high degree of openness, the fabric has high strength and dimensional stability, as demonstrated by the yarn fray test and other strength tests described above.

Although preferred embodiments of the invention have been set forth herein and specific terms have been used, they are used in an inclusive and descriptive sense and are not intended to be limiting and are intended to be within the scope of the invention. Is defined by the claims.

─────────────────────────────────────────────────── ─── Continuation of front page (51) Int.Cl. ⁷ Identification code FI theme code (reference) // D06H 5/00 D06H 5/00 (81) Designated country EP (AT, BE, CH, CY, DE, DK, ES, FI, FR, GB, GR, IE, IT, LU, MC, NL, PT, SE), OA (BF, BJ, CF, CG, CI, CM, GA, GN, GW, ML, MR, NE, SN, TD, TG), AP (GH, GM, KE, LS, MW, MZ, SD, SL, SZ, TZ, UG, ZW), EA (AM, AZ, BY, KG, KZ) , MD, RU, TJ, TM), AE, AG, AL, AM, AT, AU, AZ, BA, BB, BG, BR, BY, BZ, CA, CH, CN, CR, CU, Z, DE, DK, DM, DZ, EE, ES, FI, GB, GD, GE, GH, GM, HR, HU, ID, IL, IN, IS, JP, KE, KG, KP, KR, KZ , LC, LK, LR, LS, LT, LU, LV, MA, MD, MG, MK, MN, MW, MX, MZ, NO, NZ, PL, PT, RO, RU, SD, SE, SG, SI, SK, SL, TJ, TM, TR, TT, TZ, UA, UG, UZ, VN, YU, ZA, ZW (72) Inventor Daniel Pee Zillig, USA 29650 Bushbury, Greer, South Carolina USA Way 5 (72) Inventor Anthony Earl Waldrop United States 29642 Street 126th F-Term, Deer Creek Court, Easley, South Carolina (Reference) 3B154 AA06 AA07 AA18 AB20 BA32 BB62 DA18 DA30 4L048 AA20 AA28 AA37 AA42 AA48 AA49 AA51 AB08 AB09 AB17 AC09 AC10 AC12 AC18 BA02 BA06 BA08 CA00 CA01 CA11 DA13 DA25 EA00 EB05

Claims (37)

[Claims] 1. A woven fabric comprising a set of warp yarns and a set of weft yarns, wherein at least a plurality of yarns forming the set of warp yarns are woven in a entangled arrangement, whereby the warp yarns are yarns of the set of weft yarns. Clamped around, the woven fabric having an open area of at least about 15% and exhibiting a strength of at least about 0.5 pounds in each of the warp and weft directions when subjected to the yarn fray test. 2. The woven fabric of claim 1, wherein the woven fabric exhibits a strength in the warp direction of at least about 2 pounds and a strength in the weft direction of at least about 1 pound when subjected to a yarn fray test. 3. The woven fabric has an open area of at least about 35%.
The woven fabric described in. 4. The woven fabric has an open area of at least about 45%.
The woven fabric described in. 5. The woven fabric according to claim 1, wherein at least one of the warp set and the weft set comprises an elastomeric synthetic thread. 6. The elastomeric synthetic yarn is resistant to UV radiation such that the woven fabric has at least about 50% when measured in the elastomeric synthetic yarn direction after accelerated exposure to 225 kilojoules of UV radiation. 6. The woven fabric according to claim 5, which maintains the initial breaking strength of. 7. The elastomeric synthetic yarn is resistant to ultraviolet radiation such that the woven fabric has at least about 70% when measured in the elastomeric synthetic yarn direction after accelerated exposure to 225 kilojoules of ultraviolet radiation. 7. The woven fabric according to claim 6, which maintains the initial breaking strength of. 8. The elastomeric synthetic yarn is characterized by an elongation at break of at least about 90% and at least about 80 after accelerated exposure to 488 kilojoules of ultraviolet radiation.
The woven fabric according to claim 5, which maintains a tensile strength of%. 9. The woven fabric of claim 5, wherein the elastomeric synthetic yarn comprises at least about 40% by weight of the woven fabric. 10. The woven fabric of claim 1, wherein at least some of the intersections of the warp and weft yarns are joined. 11. At least one of the warp and weft sets comprises a bicomponent sheath / core elastomeric yarn, the sheath component being melted to join the intersections of the warp and weft set yarns. Item 10. The woven fabric according to item 10. 12. A woven fabric having a first yarn set interwoven with a second yarn set in a entangled arrangement, wherein at least one of the first yarn set and the second yarn set is an elastomer synthetic yarn. A woven fabric, comprising: the elastomeric synthetic yarn bonded to a yarn of the other yarn set of the yarn set to form a woven fabric having high dimensional stability. 13. The woven fabric of claim 12, wherein the first and second sets of yarns are interwoven to form an open woven fabric having an open space of at least about 15%. 14. The woven fabric of claim 12, wherein the first and second yarn sets are woven together to form an open woven fabric having an open space of at least about 35%. 15. The woven fabric of claim 12, wherein the first and second sets of yarns are interwoven to form an open woven fabric having an open space of at least about 45%. 16. The elastomeric synthetic yarn comprises at least about 40% by weight of the woven fabric.
13. The woven fabric according to claim 12, wherein 17. The method of claim 12, wherein the elastomeric synthetic yarn comprises a sheath / core bicomponent filament, the fusion of the bicomponent filaments joining the elastomeric synthetic yarn to a yarn of the other yarn set of the yarn set. Woven fabric as described. 18. The woven fabric of claim 12, wherein the woven fabric maintains an initial break strength of at least about 50% when measured in the elastomer synthetic yarn direction after accelerated exposure to 225 kilojoules of ultraviolet radiation. . 19. The woven fabric of claim 18, wherein the woven fabric maintains an initial break strength of at least about 70% when measured in the elastomer synthetic yarn direction after accelerated exposure to 225 kilojoules of ultraviolet radiation. . 20. The woven fabric maintains an initial breaking strength of at least about 50% when measured perpendicular to the elastomeric synthetic yarn direction after accelerated exposure to 225 kilojoules of ultraviolet radiation. Woven cloth. 21. The woven fabric maintains an initial breaking strength of at least about 50% when measured perpendicular to the elastomeric synthetic yarn direction after accelerated exposure to 225 kilojoules of ultraviolet radiation. Woven cloth. 22. The woven fabric of claim 12, wherein the woven fabric exhibits a strength of at least about 0.5 pounds in each of a first direction and a second direction when subjected to a yarn fray test. 23. The woven fabric of claim 22, wherein the woven fabric exhibits a strength of at least about 2 pounds in a first direction and a strength of at least about 1 pound in a second direction when subjected to a yarn fray test. cloth. 24. The woven fabric according to claim 12, wherein the first direction is a warp direction of fibers and the second direction is a weft direction. 25. A first plurality of elastomeric synthetic yarns extending in a first direction interwoven with a second plurality of yarns extending in a second direction substantially transverse to the first direction. Wherein the elastomeric synthetic yarns running in the first direction make up at least about 40% by weight of the woven fabric, and the elastomeric synthetic yarns comprise at least about 40% by weight.
A woven fabric characterized by an elongation at break of 90%, maintaining a tensile strength of at least about 80% after accelerated exposure to 488 kilojoules of UV radiation and interweaving the first and second plurality of yarns in a entangled configuration. cloth. 26. The woven fabric of claim 25, wherein the first and second plurality of yarns are interwoven to form an open woven fabric having an open space of at least about 15%. 27. The woven fabric of claim 25, wherein the first and second plurality of yarns are interwoven to form an open woven fabric having an open space of at least about 35%. 28. The woven fabric of claim 25, wherein the first and second plurality of yarns are interwoven to form an open woven fabric having an open space of at least about 45%. 29. The woven fabric of claim 25, wherein the first and second plurality of yarns are interwoven to define a plurality of yarn intersections and at least some of the yarn intersections are joined. 30. The woven fabric of claim 25, wherein the elastomeric synthetic yarn is a two-component sheath / core elastomeric yarn having a sheath component having a melting temperature at least about 30 ° F. below the melting temperature of the core component. 31. The woven fabric of claim 30, wherein a portion of the bicomponent sheath / core elastomeric yarn is melt bonded to a second plurality of yarns to form a plurality of bonded yarn intersections. 32. The woven fabric of claim 25, wherein the woven fabric maintains an initial breaking strength of at least about 50% when measured in the elastomer synthetic yarn direction after accelerated exposure to 225 kilojoules of ultraviolet radiation. . 33. The woven fabric of claim 32, wherein the woven fabric maintains an initial break strength of at least about 70% when measured in the elastomer synthetic yarn direction after accelerated exposure to 225 kilojoules of ultraviolet radiation. . 34. The fabric of claim 32, wherein the woven fabric maintains an initial break strength of at least about 50% when measured perpendicular to the elastomeric synthetic yarn direction after accelerated exposure to 225 kilojoules of ultraviolet radiation. Woven cloth. 35. The fabric, when subjected to a yarn fray test, exhibits a strength of at least about 0.5 pounds in each of a first direction and a second direction.
The woven fabric described in. 36. The woven fabric of claim 35, wherein the woven fabric exhibits a strength of at least about 2 pounds in a first direction and a strength of at least about 1 pound in a second direction when subjected to a yarn fray test. cloth. 37. The woven fabric according to claim 25, wherein the first direction is a warp direction of the woven fabric and the second direction is a weft direction.