EP1232300B1 - Gewebe inbesondere anwendbar beim herstellen insassentragkonstruktionen - Google Patents

Gewebe inbesondere anwendbar beim herstellen insassentragkonstruktionen Download PDF

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Publication number
EP1232300B1
EP1232300B1 EP00973720A EP00973720A EP1232300B1 EP 1232300 B1 EP1232300 B1 EP 1232300B1 EP 00973720 A EP00973720 A EP 00973720A EP 00973720 A EP00973720 A EP 00973720A EP 1232300 B1 EP1232300 B1 EP 1232300B1
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EP
European Patent Office
Prior art keywords
yarns
fabric
yarn
textile fabric
yarn set
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
EP00973720A
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English (en)
French (fr)
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EP1232300A1 (de
Inventor
Douglas J. Salway
Jan L. Williams
Daniel P. Gillig
Anthony R. Waldrop
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Milliken and Co
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Milliken and Co
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Publication of EP1232300B1 publication Critical patent/EP1232300B1/de
Anticipated expiration legal-status Critical
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Classifications

    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D9/00—Open-work fabrics
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D19/00—Gauze or leno-woven fabrics
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/30—Woven fabric [i.e., woven strand or strip material]
    • Y10T442/3008—Woven fabric has an elastic quality
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/30—Woven fabric [i.e., woven strand or strip material]
    • Y10T442/3008—Woven fabric has an elastic quality
    • Y10T442/3024—Including elastic strand or strip
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/30—Woven fabric [i.e., woven strand or strip material]
    • Y10T442/3146—Strand material is composed of two or more polymeric materials in physically distinct relationship [e.g., sheath-core, side-by-side, islands-in-sea, fibrils-in-matrix, etc.] or composed of physical blend of chemically different polymeric materials or a physical blend of a polymeric material and a filler material
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/30—Woven fabric [i.e., woven strand or strip material]
    • Y10T442/3146—Strand material is composed of two or more polymeric materials in physically distinct relationship [e.g., sheath-core, side-by-side, islands-in-sea, fibrils-in-matrix, etc.] or composed of physical blend of chemically different polymeric materials or a physical blend of a polymeric material and a filler material
    • Y10T442/3154—Sheath-core multicomponent strand material
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/30—Woven fabric [i.e., woven strand or strip material]
    • Y10T442/3179—Woven fabric is characterized by a particular or differential weave other than fabric in which the strand denier or warp/weft pick count is specified
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/30—Woven fabric [i.e., woven strand or strip material]
    • Y10T442/3179—Woven fabric is characterized by a particular or differential weave other than fabric in which the strand denier or warp/weft pick count is specified
    • Y10T442/322—Warp differs from weft
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/30—Woven fabric [i.e., woven strand or strip material]
    • Y10T442/3179—Woven fabric is characterized by a particular or differential weave other than fabric in which the strand denier or warp/weft pick count is specified
    • Y10T442/322—Warp differs from weft
    • Y10T442/3228—Materials differ
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/30—Woven fabric [i.e., woven strand or strip material]
    • Y10T442/3179—Woven fabric is characterized by a particular or differential weave other than fabric in which the strand denier or warp/weft pick count is specified
    • Y10T442/322—Warp differs from weft
    • Y10T442/3228—Materials differ
    • Y10T442/326—Including synthetic polymeric strand material
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/30—Woven fabric [i.e., woven strand or strip material]
    • Y10T442/3179—Woven fabric is characterized by a particular or differential weave other than fabric in which the strand denier or warp/weft pick count is specified
    • Y10T442/322—Warp differs from weft
    • Y10T442/3228—Materials differ
    • Y10T442/326—Including synthetic polymeric strand material
    • Y10T442/3285—Including polyester strand material
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/30—Woven fabric [i.e., woven strand or strip material]
    • Y10T442/3976—Including strand which is stated to have specific attributes [e.g., heat or fire resistance, chemical or solvent resistance, high absorption for aqueous composition, water solubility, heat shrinkability, etc.]

Definitions

  • the invention generally relates to woven fabric constructions. More specifically, the invention relates to woven fabrics having good durability, strength, dimensional stability and ventilation properties which are particularly adapted for use in the production of occupant support structures such as seating, bedding and the like.
  • occupant support structures such as seating, bedding, and the like are generally constructed from a fabric support secured to some form of frame.
  • occupant support structures include additional support elements such as springs, cushions, pads, straps, webs or the like. Such additional support elements typically constitute a large part of the overall weight and dimension of the occupant support structures.
  • the weight of the overall structure can influence variables such as fuel efficiency, freight charges, and the like.
  • many occupant support structures for home and office use e.g. chairs, sofas and the like
  • Another disadvantage associated with many conventional forms of occupant support structures is that a number of the materials typically used to produce these structures tend to feel cold or hot to a user depending on the particular environmental conditions. For example, the tendency for an automobile seat to feel hot can be readily appreciated by anyone who has sat on a leather car seat in the summer heat.
  • the materials are generally not breathable, and therefore they tend to block the flow of air past adjacent portions of a user's body. As a result, the back of the legs of a seated individual can become sweaty and uncomfortable following long periods of sitting on a seat formed of conventional material.
  • the difficulty and costs associated with assembly of occupant support structures generally are related to the number of structural elements required for their production. To reduce the complexity of the assembly process, it may therefore in many cases be desirable to manufacture occupant support structures using a minimal number of elements. However, the reduction in the number of elements must be balanced against the need to achieve particular performance capabilities.
  • the materials used to produce the occupant support structures are exposed to a variety of degradory forces.
  • seats in automobiles are exposed to a wide range of temperatures, compressive forces, lateral shearing forces and the like.
  • such support structures are commonly exposed to ultra-violet (UV) irradiation on an extended basis from the sunlight which passes through the windshield and the windows.
  • UV irradiation tends to undesirably degrade many kinds of materials, rendering them unsuitable for use as surface fabrics in environments where they can be exposed to a high degree of UV irradiation. Therefore, with the minimization of elements, the strength and durability of the elements that are utilized becomes increasingly important.
  • manufacturers must typically take other properties such as tactile properties, hand, drape and the like into consideration to ensure a proper balance of properties is achieved for the particular end use for which the fabric is being manufactured.
  • the McLarty '888 patent describes a knit furniture support fabric having multi-directional stretch characteristics and possessing sufficient strength and durability to function as a support in a seating or bed structure.
  • the furniture support fabric is a four bar knit structure including two yarns of textured polyester and two yarns of elastomeric monofilament knit together such that the fabric has an elongation at break of at least 17 percent in both the warp and fill directions. While providing good physical properties for many end use applications, it has been found that fabrics made according to the McLarty '789 and '888 patents have a harsher hand than is desired for some particular end use applications.
  • U.S. Patent No. 4,469,739 to Gretzinger et al. describes woven furniture support materials made in part from elastomer monofilaments and in part from a non-elastomeric yarn.
  • the non-elastomeric yarn is described as being provided in the warp direction of the fabric in the preferred embodiment of the structure.
  • the patent describes that the yarns can be melted at their intersections with each other, or alternatively can be affixed to each other at the intersections by selecting the weaving pattern to be of such a configuration that the yarn will lock in place about the filament, thereby obviating the need for adhesive or melting of the elastomer.
  • the Waldrop patent describes a fabric having a plurality of elastomeric synthetic yarns running in a first direction interwoven with a plurality of synthetic yarns running in a second direction substantially transverse to the first direction, where the elastomeric synthetic yarns running in the first direction comprise not less than about 40 percent by weight of the textile fabric.
  • the elastomeric yarns running in the first direction are further characterized by the fact they have an elongation at break of not less than about 50 percent, and they retain not less than about 80 percent of their tensile strength upon accelerated exposure to 488 kilojoules of ultraviolet irradiation.
  • the patent describes that the fabric is preferably a woven fabric, and particularly, one which is woven in a barathea weave construction. Because of its resistance to degradation from exposure to UV irradiation, the fabric can be used as a surface material in automotive seating applications.
  • WO 98/06570 discloses a textile with weft yarns and warp yarns that are interwoven into a textile having a planar permeable structure, a portion of the warp and weft yarns comprising load bearing yarns having a low elongation.
  • the textile comprises a leno yarn.
  • the instant invention overcomes disadvantages associated with conventional structures through the provision of a fabric having desirable levels of durability, strength, dimensional stability, and elastomeric properties; rendering it particularly well-suited for use in the manufacture of occupant support structures.
  • the fabric of the invention has a good hand and retains desirable physical properties, even after extended periods of exposure to ultraviolet irradiation. As a result, it performs well as a surface fabric in occupant support structures such as automobile seats and the like.
  • the fabric of the instant invention has a large degree of openness, so as to provide good ventilation characteristics. Because of its unique construction, the fabric can be secured to a frame alone (i.e., without other fabric layers) to form a support structure or it can be used in combination with other layers as desired. Furthermore, the fabric can be cut into pieces of desired shape and size, and fabricated into an end use product without undesirable levels of fabric degradation through raveling or the like.
  • the fabrics of the invention achieve the desired properties by utilizing elastomeric synthetic yarns in an open weave structure formed by first and second sets of intersecting yarns.
  • the fabric is woven in a leno weave so that warp yarns of the fabric are locked around at least some of the fill yarns.
  • Yarns of the first and second yarn sets are also desirably supplementally secured together at their intersections.
  • the elastomeric synthetic yarns are preferably provided in the warp, and are of the bicomponent sheath/core variety.
  • the sheath component desirably has a melting temperature which is below that of the core component, so that the sheath can be melted subsequent to weaving to lock the yarns of the respective yarn sets together at their intersections.
  • the other yarn set may or may not include elastomeric synthetic yarns, with the yarn used desirably being selected to provide the fabric with a particular combination of physical characteristics, such as a good hand and aesthetic appearance.
  • At least some of the yarns forming the fabric are desirably UV-resistant so that the fabric retains at least about 50%, and more preferably at least about 70% of its initial breaking strength when measured in the elastomeric synthetic yarn direction and at least about 50% of its initial breaking strength when measured perpendicular to the elastomeric synthetic yarn direction following accelerated exposure to 225 kilojoules of UV irradiation.
  • the fabric has high strength and dimensional stability, and resists unraveling.
  • the fabric is also desirably open, so that at least about 15% of a given area of the fabric is open area, and more preferably at least about 30%. Even more preferred is that the fabric constitutes at least about 35%, and more preferably at least about 40% open area.
  • fabrics having at least about 45% open area can be made according to the instant invention, while retaining sufficient strength and dimensional stability to enable them to be used in the formation of occupant support structures.
  • products made according to the invention using yarns which are resistant to UV irradiation are particularly useful in the formation of occupant support structures which are exposed to UV irradiation on an extended basis, such as automotive seating.
  • the fabric of the instant invention is constructed to provide a high degree of fabric openness.
  • at least about 15% of the surface area of a piece of fabric constitutes open space (i.e. space between the fibers or yarns forming the fabric), and more preferably at least about 30%.
  • at least about 35% of the fabric is open space, and more preferably about 40%.
  • the fabric according to the invention desirably includes a first set of yarns extending in a first direction and a second set of yarns extending in a second direction which is generally transverse to the first direction.
  • the fabric is desirably a woven fabric in which one of the first and second yarn sets is a warp yarn set and the other of the first and second yarn sets is a weft (i.e. filling) yarn set.
  • the fabric is woven to include a plurality of elastomeric synthetic yarns in at least one of the first and second yarn sets, preferably in the warp yarn set.
  • elastomeric synthetic yarns are included in both the first and second yarn sets.
  • the elastomeric synthetic yarns are monofilament yarns having an elongation at break of at least about 50%, and preferably a tensile strength of at least about 8 pounds force prior to weaving, and more preferably at least about 8.5 pounds force. Even more preferably, the elastomeric synthetic yarns are monofilament yarns having an elongation at break of at least about 75%, and more preferably at least about 90%, and even more preferably at least about 100%.
  • the elastomeric synthetic yarns are of the sheath/core variety in which the sheath has a lower melting temperature than that of the core component.
  • the melting temperature of the sheath is desirably at least about 30° F lower than that of the core, for reasons which will be discussed more fully hereinafter.
  • Elastomeric synthetic yarns which have been found to perform particularly well in the invention are distributed under the tradename ELAS-TER® by Johns Manville of Spartanburg, SC (formerly Hoechst Celanese.)
  • the yarns forming the second yarn set can be any of a variety of materials, depending on the intended end use of the fabric.
  • the second yarn set also includes elastomeric synthetic yarns, either alone or in combination with one or more other types of yarns.
  • the fill can include other types of elastomeric yarns, polyester, nylon, natural Taslan polyester, elastomeric/Taslan polyester yarn combinations, polyester wrapped ELAS-TER® yarns, combinations thereof, or any other type of yarn or yarn combination which achieves the desired end properties.
  • the second yarn set can be included in most forms of the invention.
  • other types of yarns in the second yarn set can be included in many cases.
  • a yarn in the second yarn set which provides the fabric with a soft hand or the like (e.g. through the use of a textured or spun yarn and in particular, one having an overall cross-sectional diameter which is greater than that of the elastomeric synthetic yarn, so that it extends outwardly from the fabric to form an aesthetically pleasing fabric surface.
  • the second yarn set can be devoid of elastomeric synthetic yarns, depending on the particular end use intended for the fabric and physical characteristics desired.
  • a single yarn can be inserted in each shed during the weaving process or a plurality of yarns can be inserted in one or more of the sheds.
  • the elastomeric yarns can be provided in the fill while other types of yarns are used to form the warp. However, it is preferred to provide the elastomeric synthetic yarns in at least the warp direction.
  • the second yarn set includes a Taslan polyester yarn about 600 - 2200 denier in size.
  • This yarn can be used alone to form the second yarn set, or it can be used in combination with an elastomeric synthetic yarn similar to or the same as that used in the first yarn set.
  • the elastomeric synthetic yarn component and the other yarn component can be combined prior to weaving (e.g. through a texturing or twisting process or the like), or the two components can be inserted together during the weaving process, without first being combined together.
  • the particular arrangement of the filling yarns will be selected to achieve the physical and aesthetic properties desired.
  • the fabric is desirably woven in a construction wherein at least some of the warp and fill yarns are locked together by virtue of the weave construction rather than simply intersecting in the manner of a plain weave construction.
  • the weave construction used to stabilize the points of intersection is a leno weave construction or a variation of a leno weave construction.
  • a leno weave includes pairs of warp yarns which cross as they encircle and secure the filling yarns.
  • the term "leno" is intended in its broadest meaning and to include all variations of leno weave.)
  • all of the warp yarns are woven in a leno fashion; however, fabrics having only a portion of the warp yarns woven in a leno fashion are also within the scope of the instant invention.
  • a pattern of alternating leno and plain woven warp yarns can be utilized.
  • other weave constructions that secure at least some of the yarn intersections from relative motion can be used within the scope of the invention.
  • At least some of the points of intersection are also supplementally secured from relative motion with respect to each other.
  • at least a portion of the yarns used to construct the woven fabric are thermoplastic, so that they can be melted during a heat setting operation to secure the points of intersection of yarns in the respective first and second yarn sets from relative motion.
  • At least some of the points of intersection are secured by both the particular weave construction utilized and by a supplemental securement.
  • At least some of the yarns used to form the fabric are sheath/core bicomponent yarns, having a sheath component with a lower melting temperature than the core component.
  • the fabric can be subjected to a temperature greater than that of the melting point of the sheath (but preferably below the melting point of the core component) to melt the sheath, and when the sheath is resolidified, it can serve to bond the woven fabric together at the point of yarn intersection.
  • the fabric is also designed to be resistant to UV irradiation, in order that it retains its strength and other physical characteristics even after extended exposure to UV irradiation.
  • at least some of the yarns, and preferably substantially all of the yarns, forming the fabric are resistant to UV irradiation.
  • the yarns desirably retain a substantial portion of their original tensile strength and elongation characteristics following exposure to high levels of UV irradiation for extended periods of time.
  • at least one of the first and second yarn sets contains elastomeric synthetic yarns which are UV resistant.
  • UV-resistant elastomeric synthetic yarns are utilized to form the warp yarns of the fabric.
  • the UV-resistant elastomeric synthetic yarns desirably retain at least about 80%, and more preferably at least about 90%, of their original tensile strength upon accelerated exposure to 488 kilojoules of UV irradiation in compliance with SAE testing standard J1885.
  • the UV-resistant elastomeric synthetic yarns retain at least about 95% of their tensile strength upon accelerated exposure to UV irradiation.
  • a sample of an elastomeric synthetic yarn useful in performing the instant invention was tested prior to weaving, where it exhibited a tensile strength of approximately 8.9 pounds force and an elongation at break of about 124%, and after accelerated exposure to UV irradiation at a level of 488 kilojoules in compliance with SAE testing standard J1885 exhibited a tensile strength of 7.1 pounds force and an elongation at break of approximately 115%.
  • fabrics of the instant invention are desirably woven in a leno weave with the elastomeric synthetic yarns forming at least about 40% by weight of the total fabric, and are woven to produce a relatively open structure.
  • a fabric is leno woven using a 2250 denier elastomeric monofilament polyester disposed in the fabric at a weave density of about 20 ends per inch.
  • the filling is desirably a polyester yarn which is 300 denier or greater in size, and which may or may not include an elastomeric synthetic yarn component.
  • a 1650 denier Taslan yarn has been found to perform well in the instant invention.
  • the fill density is desirably from about 4 picks per inch to about 30 picks per inch.
  • a plurality of fill yarns of one or more types may be provided in a single shed.
  • the fabrics which utilize sheath/core bicomponent yarns as the elastomeric synthetic yarns, are heat treated to melt the sheath component and secure the first and second yarns sets at their respective yarn intersections. The yarns are then allowed to cool so that the melted material re-solidifies to form a good bond between the yarns of the respective yarn sets.
  • Fabrics made according to the instant invention desirably retain at least about 50%, and more preferably at least about 70% of their original breaking strength when measured in the elastomeric synthetic yarn direction and at least about 50% of their original breaking strength when measured in the other generally transverse direction following exposure to a cumulative irradiation of 225 kilojoules in accordance with SAE Standard J1885.
  • the fabric has an elongation at break in the elastomeric synthetic yarn direction of at least about 70% before and after exposure to accelerated levels of UV irradiation of 225 kilojoules and they retain at least about 50%, and more preferably at least about 70% of their tensile strength in the elastomeric synthetic yarn direction following accelerated UV irradiation exposure.
  • the fabrics have unique combinations of strength, durability, and dimensional stability as well as desirable aesthetic properties such as hand. Additionally, the fabrics made according to the invention can be cut and sewn without raveling, rendering them easier to use in the production of occupant support structures than prior art fabrics, and minimizing fabric waste due to raveling.
  • Fabrics were prepared as follows and tested for purposes of comparison according to the tests described below. Each of the fabrics was produced on a standard rapier weaving machine utilizing a reed width of 69 inches and a beam width of 69 inches. The fabrics were woven in the respective manner described, and heat setting was performed at about 390° F to bond the intersections of the yarn sets.
  • Sample A was fabricated in a conventional manner, to resemble a commercially-available product.
  • the fabric was woven in a leno construction to include oval-shaped elastomeric yarns in the warp and elastomer/Taslan polyester yarns in the fill. None of the yarns used were UV stabilized, and the fabric was not heat set in the manner of the instant invention.
  • Sample B was manufactured according to the instant invention.
  • the fabric was formed in a leno weave construction with the warp being formed from 1000 denier UV- stabilized ELAS-TER® yarns, while the fill included elastomer/Taslan polyester yarns.
  • the fabric was heat set to melt the sheath of the ELAS-TER® yarns and secure the points of intersection between the warp and fill yarn sets.
  • Sample C was manufactured according to the instant invention.
  • the fabric was formed in a leno weave construction using 2250 denier UV-stabilized ELAS-TER® yarns in the warp and with two elastomer/Taslan polyester combination yarns and two natural Taslan polyester yarns being inserted in alternating fashion in each shed.
  • each shed included a filling yarn combination of one elastomer/Taslan yarn, one natural Taslan yarn, a second elastomer/Taslan yarn, and a second natural Taslan yarn.
  • the fabric was heat set according to the instant invention to melt the ELAS-TER® yarns, to thereby supplementally secure the points of intersection between the warp and fill yarn sets.
  • Sample D was manufactured according to the instant invention.
  • the fabric was formed in a leno weave construction using 2250 denier UV-stabilized ELAS-TER® yarns in the warp and 400 denier ELAS-TER® wrapped with 70 denier polyester yarn in the fill.
  • the fabric was heat set according to the instant invention to melt the ELAS-TER® yarns, to thereby supplementally secure the points of intersection between the warp and fill yarn sets.
  • Sample E was manufactured according to the instant invention.
  • the fabric was formed in a leno weave construction using 1000 denier UV-stabilized ELAS-TER® yarns in the warp and a 400 denier ELAS-TER® wrapped with 70 denier polyester yarn in the fill.
  • the fabric was heat set according to the instant invention to melt the ELAS-TER® yarns and supplementally secure the points of intersection between the warp and fill yarn sets.
  • the fabric was tested using a Yarn Unravel Test as described below. The procedure closely followed the Trap Tear Test described in ASTM D1117-14 and was conducted as follows: Fabric samples were obtained by cutting 3 inch X 3 inch swatches of each of the fabrics to be tested. A Sintech Tensile tester was used having top and bottom jaws which were 2 inches X 3 inches. A gauge length of about 3 ⁇ 4 inch was used to obtain about 2 inches of yarn unraveling. The cross head speed was set at 12 inches per minute. The sample was clamped in the bottom jaws of the tensile tester first. One yarn was pulled loose one inch and clamped in the upper jaw of the tensile tester.
  • the fabric manufactured according to conventional method i.e. Sample A
  • the fabrics made according to the instant invention provided significantly greater resistance to yarn unraveling, as evidenced by the significantly higher forces required to unravel yarns in each of the warp and fill directions.
  • fabric made according to the instant invention exhibited a mean value of at least about .5 pounds strength resistance to unraveling in each of the warp and fill directions.
  • the fabrics had a resistance of at least about 2 pounds strength in the warp direction and at least about 1 pound in the fill direction.
  • the fabric had a resistance of at least about 8 pounds in the warp direction and at least about 3 pounds in the fill direction.
  • Even more preferable is a fabric having at least about 15 pounds in the warp direction and at least about 4 pounds in the fill direction.
  • fabrics made according to the instant invention exhibited much greater strength than that of the conventional construction (Sample A).
  • fabrics made according to the instant invention have a resistance of at least about 4 pounds in the warp and at least about 10 pounds in the fill, more preferably has a warp resistance of at least about 15 pounds, more preferably at least about 80 pounds, and more preferably at least about 90 pounds.
  • resistance in the filling is desirably 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 further subjected to a Skewer/Tear Test as follows: a piece of the fabric being tested was inserted within a slot formed in the side edge of a small metal plate.
  • the slot was approximately 1/2 inch ( ⁇ 1.1 cm) in depth, such that about a 1/2 inch ( ⁇ 1.1 cm) section of the edge of the fabric was contained within the slot.
  • the metal plate included first and second openings approximately 3/32 inch ( ⁇ .025 cm) in diameter which were spaced apart about 1/4 inch ( ⁇ .065 cm) from each other and spaced inwardly from the edge of the plate about 7/16 inch ( ⁇ 5 cm), so that the openings overlay the slot formed in the side of the plate.
  • a handle having first and second prongs extending outwardly therefrom was provided, with the prongs being spaced apart the same distance as the openings in the metal plate.
  • the prongs were then inserted through the openings (which extend through the entire dimension of the plate) such that the fabric was effectively skewered in position within the slot at a position about 7/16 inch ( ⁇ .5 cm) inwardly from its edge.
  • the metal plate (holding the first end of the fabric) and free end of the fabric were then pulled apart by a machine designed to measure the amount of force required to pull the 7/16 inch ( ⁇ .5 cm) edge of the fabric loose from the rest of the fabric structure.
  • the fabrics of the instant invention have superior strength and dimensional stability as compared with those of the prior art.
  • the superior dimensional stability and ravel resistance enables the fabrics of the instant invention to be cut and manipulated in the fabrication of the end use products, a feature that was heretofore impossible with the comparable prior art fabrics.
  • Samples B, C and D were also tested to determine their "openness", along with a Sample F which was prepared as follows:
  • Sample F was manufactured according to the instant invention.
  • the fabric was woven in a leno construction using 2250 denier UV-stabilized ELAS-TER® yarns in the warp and a pick of natural Taslan polyester and a pick of 400 denier ELAS-TER® in each shed of the fill.
  • the fabric was heat set according to the instant invention to melt the ELAS-TER® yarns, to thereby supplementally secure the points of intersection between the warp and fill yarn sets.
  • the fabrics of the invention described have at least about 15% open area, more preferably at least about 30%, even more preferably at least about 35%, and even more preferably at least about 40%. Furthermore, fabrics having at least about 45% open area can be produced and as indicated by Sample D, have desirably strength levels to enable their use in a variety of end use products.
  • a typical barathea fabric (similar to that described in commonly-assigned U.S. Patent No. 5,856,249 described above) would only have about 5% openness, rather than the significant openness achieved with the fabrics of the instant invention. As noted above, this high amount of openness enhances the comfort characteristics of the fabric, as well as providing a desirable aesthetic appearance. In addition, despite their high degree of openness, the fabrics have good strength and dimensional stability, as evidenced by the Yarn Unravel Test and other strength tests described above.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Woven Fabrics (AREA)
  • Multicomponent Fibers (AREA)
  • Treatment Of Fiber Materials (AREA)
  • Laminated Bodies (AREA)
  • Air Bags (AREA)

Claims (15)

  1. Textilstoff umfassend:
    einen ersten Satz Garne, der mit einem zweiten Satz Garne in einer Gazegewebekonfiguration derart verwebt ist, daß die Garne des ersten Satzes Garne an den Garnen des zweiten Satzes Garne an ihren Kreuzungspunkten befestigt sind, wobei die Garne des ersten Satzes Garne einen Kern und eine Hülle umfassen, und wobei die Hüllen der Garne des ersten Satzes Garne geschmolzen werden, um die Kreuzungspunkte zwischen dem ersten Satz Garne und dem zweiten Satz Garne zu befestigen,
    dadurch gekennzeichnet, daß der erste Satz Garne elastomere synthetische Monofilamentgarne mit einer Bruchdehnung von mindestens 50 % umfaßt.
  2. Textilstoff nach Anspruch 1, wobei die Garne des zweiten Satzes Garne texturierte Garne umfassen.
  3. Textilstoff nach Anspruch 1, wobei die Garne des zweiten Satzes Garne gesponnene Garne umfassen.
  4. Textilstoff nach Anspruch 1, wobei die Garne des zweiten Satzes Garne insgesamt einen Querschnittsdurchmesser aufweisen, der größer ist als der der Garne des ersten Satzes Garne.
  5. Textilstoff nach Anspruch 1, wobei die Hülle der Garne des ersten Satzes Garne eine niedrigere Schmelztemperatur aufweisen als der Kern.
  6. Textilstoff nach Anspruch 1, wobei die Garne des ersten Satzes Garne Monofilamentgarne umfassen.
  7. Textilstoff nach Anspruch 1, wobei die elastomeren synthetischen Monofilamentgarne des ersten Satzes Garne eine Bruchdehnung von mindestens 75 % aufweisen.
  8. Textilstoff nach Anspruch 1, wobei die elastomeren synthetischen Monofilamentgarne des ersten Satzes Garne eine Bruchdehnung von mindestens 90 % aufweisen.
  9. Textilstoff nach Anspruch 1, wobei die elastomeren synthetischen Monofilamentgarne des ersten Satzes Garne eine Bruchdehnung von mindestens 100 % aufweisen.
  10. Textilstoff nach Anspruch 1, wobei die Garne des zweiten Satzes Garne ein elastomeres synthetisches Garn umfassen.
  11. Textilstoff nach Anspruch 1, wobei die Garne des zweiten Satzes Garne elastomere synthetische Garne und nichtelastomere synthetische Garne umfassen.
  12. Textilstoff nach Anspruch 1, wobei die Garne des zweiten Satzes Garne Polyester umfassen.
  13. Textilstoff nach einem der vorhergehenden Ansprüche, wobei mindestens 15 % einer gegebenen Fläche des Stoffes offen ist.
  14. Textilstoff nach einem der vorhergehenden Ansprüche, wobei mindestens 35 % einer gegebenen Fläche des Stoffes offen ist.
  15. Textilstoff nach einem der vorhergehenden Ansprüche, wobei mindestens 45 % einer gegebenen Fläche des Stoffes offen ist.
EP00973720A 1999-11-26 2000-10-19 Gewebe inbesondere anwendbar beim herstellen insassentragkonstruktionen Expired - Lifetime EP1232300B1 (de)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US449789 1999-11-26
US09/449,789 US20020098759A1 (en) 1999-11-26 1999-11-26 Woven fabrics particularly useful in the manufacture of occupant support structures
PCT/US2000/029049 WO2001038621A1 (en) 1999-11-26 2000-10-19 Woven fabrics particularly useful in the manufacture of occupant support structures

Publications (2)

Publication Number Publication Date
EP1232300A1 EP1232300A1 (de) 2002-08-21
EP1232300B1 true EP1232300B1 (de) 2005-12-28

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EP00973720A Expired - Lifetime EP1232300B1 (de) 1999-11-26 2000-10-19 Gewebe inbesondere anwendbar beim herstellen insassentragkonstruktionen

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US (2) US20020098759A1 (de)
EP (1) EP1232300B1 (de)
JP (1) JP2003515011A (de)
KR (1) KR20020053884A (de)
CN (1) CN1399692A (de)
AT (1) ATE314509T1 (de)
AU (1) AU1219801A (de)
BR (1) BR0015943A (de)
CA (1) CA2392022A1 (de)
CZ (1) CZ20021737A3 (de)
DE (1) DE60025258T2 (de)
ES (1) ES2250209T3 (de)
PL (1) PL356643A1 (de)
WO (1) WO2001038621A1 (de)

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US7273562B2 (en) 2002-04-17 2007-09-25 Nutech 03, Inc. Ozone injection method and system
CN101324001B (zh) * 2008-07-17 2010-06-02 阮齐有 Pvc涂覆高强度涤纶长丝纱罗面料的生产方法
GB2492644B (en) * 2011-07-04 2018-12-05 Don & Low Ltd Improved polymer fabrics
IN2014KN01702A (de) * 2012-03-01 2015-10-23 Groz Beckert Kg
CN103572493A (zh) * 2012-07-27 2014-02-12 东莞超盈纺织有限公司 用以制造超强抗疲劳弹性织物的方法
US10612174B2 (en) 2012-11-07 2020-04-07 Standard Textile Co., Inc. Top cover with wash activated patterning
US20140123362A1 (en) * 2012-11-07 2014-05-08 Standard Textile Co., Inc. Woven stretch fabric bath robe
US9719196B2 (en) * 2015-04-07 2017-08-01 Mahmoud M Salama Interlocking weave for high performance fabrics
CN107849758B (zh) * 2015-06-08 2022-02-08 费德罗-莫格尔动力系有限责任公司 透明的抗端部磨损且抗emi的纺织套筒及构建方法
TWI606159B (zh) * 2015-11-19 2017-11-21 Elastic webbing modified structure with breathable effect
TW201718968A (zh) * 2015-11-19 2017-06-01 K S Webbing Co Ltd 具黏扣及透氣效果之彈性織帶改良結構
US11060215B2 (en) 2017-01-26 2021-07-13 Bright Cheers International Limited Reinforced composite fabric and method for preparing the same
JP6379237B2 (ja) * 2017-02-14 2018-08-22 ブライト チアーズ インターナショナル リミテッド 強化複合布地及びその製造方法
US10499707B2 (en) * 2017-10-18 2019-12-10 Reebok International Limited Articles of footwear having a leno woven upper with a bladder component
GB2571547B (en) * 2018-03-01 2020-09-09 Don & Low Ltd Improvements in or relating to polymer materials
JP2021526105A (ja) * 2018-03-01 2021-09-30 コンフォート コンセプツ， エルエルシー 織りカバー付き座席パッド
JP7648046B2 (ja) * 2020-04-20 2025-03-18 サンコ テキスタイル イスレットメレリ サン ベ ティク エーエス 呼吸用マスクおよびその製造方法
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ES8600431A1 (es) * 1982-08-12 1985-10-01 Du Pont Un material de soporte para mobiliario en configuracion tejida
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AU2672697A (en) * 1996-08-14 1998-03-06 Tensar Corporation, The Bonded composite engineered mesh structural textiles

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PL356643A1 (en) 2004-06-28
US20020098759A1 (en) 2002-07-25
CZ20021737A3 (cs) 2002-09-11
BR0015943A (pt) 2002-08-27
US20030124933A1 (en) 2003-07-03
JP2003515011A (ja) 2003-04-22
DE60025258T2 (de) 2006-08-24
ES2250209T3 (es) 2006-04-16
ATE314509T1 (de) 2006-01-15
AU1219801A (en) 2001-06-04
CN1399692A (zh) 2003-02-26
CA2392022A1 (en) 2001-05-31
WO2001038621A1 (en) 2001-05-31
EP1232300A1 (de) 2002-08-21
DE60025258D1 (de) 2006-02-02
KR20020053884A (ko) 2002-07-05

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