U.S. patent application number 10/078184 was filed with the patent office on 2002-08-22 for low abrasion elastomeric fabric.
Invention is credited to Josey, Steven W., Waldrop, Anthony R., Zeiler, Bernhard.
Application Number | 20020112771 10/078184 |
Document ID | / |
Family ID | 26760202 |
Filed Date | 2002-08-22 |
United States Patent
Application |
20020112771 |
Kind Code |
A1 |
Waldrop, Anthony R. ; et
al. |
August 22, 2002 |
LOW ABRASION ELASTOMERIC FABRIC
Abstract
An elastomeric fabric woven in a leno weave, with the warp yarns
being elastomeric yarns. The elastomeric warp yarns have a minor
axis disposed in the direction perpendicular to the fabric surface.
The fabric is calendered to reduce the thickness of the elastomeric
yarns along the minor axis at the cross-over of the warp yarns in
the leno weave.
Inventors: |
Waldrop, Anthony R.;
(Easley, SC) ; Zeiler, Bernhard; (Moore, SC)
; Josey, Steven W.; (Moore, SC) |
Correspondence
Address: |
Milliken & Company
Legal Department, M-495
P.O. Box 1927
Spartanburg
SC
29304
US
|
Family ID: |
26760202 |
Appl. No.: |
10/078184 |
Filed: |
February 19, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60270684 |
Feb 22, 2001 |
|
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Current U.S.
Class: |
139/50 |
Current CPC
Class: |
Y10T 442/3008 20150401;
D03D 19/00 20130101; Y10T 442/322 20150401; D03D 15/56 20210101;
Y10T 442/3228 20150401 |
Class at
Publication: |
139/50 |
International
Class: |
D03C 007/00 |
Claims
What is claimed is:
1. A fabric having a first set of yarns and a second set of yarns
interwoven in a leno weave having a fabric thickness direction,
wherein various of the yarns from the first set of yarns cross over
each other at cross over points to form the leno weave, wherein the
first set of yarns comprise elastomeric yarns with a cross section
having a yarn thickness in a minor axis oriented substantially in
the direction of the fabirc thickness direction and a yarn width in
a major axis oriented substantially perpendicular to the minor
axis, and wherein the minimum size of the yarn thickness of the
elastomeric yarns is located at the cross over points.
2. The fabric according to claim 1, wherein the yarn thickness of
the elastomeric yarns at the cross over point is from about 60% to
about 82% smaller than the yarn width.
3. The fabric according to claim 1, wherein the ratio of yarn width
to yarn thickness of the elastomeric yarn is from about 1.8 to
about 2.1 at the cross over point.
4. The fabric according to claim 1, wherein the fabric thickness at
the cross over point 105 not greater than about the mean fabric
thickness.
5. The fabric according to claim 1, wherein the second set of yarns
includes carbon impregnated yarns.
6. A method of forming an elastomeric fabric, comprising the steps
of: weaving a leno weave fabric with elastomeric yarns in a first
direction interwoven with a second yarn set in a second direction,
wherein the yarns crossing over each other to product the leno
weave are the elastomeric yarns and wherein the cross over point is
the location were elastomeric yarns cross over each other; and
calandering the leno weave fabric to reduce the thickness of the
elastomeric yarns at the cross over points.
7. The method according to claim 6, wherein the step of calandering
includes applying the calendering pressure at a temperature from
about 60 F. to about 100 F.
Description
PRIORITY
[0001] Priority is hereby claimed under 35 USC .sctn.119 to
copending provisional application Serial No. 60/270,684, filed on
Feb. 22, 2001, which is hereby incorporated herein by specific
reference thereto.
BRIEF DESCRIPTION OF THE DRAWINGS
[0002] Elastomeric fabrics are typically fabrics manufactured with
a monafilament elastomeric yarn disposed in at least one direction
of the fabric. Elastomeric fabrics have found wide spread use in
areas such as seating. In seating, elastomeric fabric can provide
both the exterior surface, and the support for the user of the
seat. However, it has been discovered that elastomerics can create
a higher abrasion on other fabrics that engage the elastomeric
fabric, such as on garments of the users sitting in the seat.
Therefore, there is a need for elastomeric fabrics which have a
lower abrasion factor.
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] The invention can be better understood with reference to the
drawings, in which:
[0004] FIG. 1 is a leno weave elastomeric fabric incorporating the
present invention.
[0005] FIG. 2 is an enlarged plan view of a portion of the fabric
from FIG. 1, illustrating warp yarns at the point of intersection
where the warp yarns cross over each other.
[0006] FIG. 3 is an enlarged cross-sectional view of the portion of
the fabric along line 3-3 in FIG. 2.
[0007] FIGS. 4A and 4B are enlarged cross-sectional views of the
warp yarns along section lines 4A-4A and 4B-4B, respectively, in
FIG. 2.
DETAILED DESCRIPTION
[0008] Referring now to the figures, and in particular to FIGS. 1,
2, and 3, there is shown elastomeric fabric 100 having a warp
direction 101, a fill direction 102, and a thickness 103. The
elastomeric fabric 100 generally includes warp yarns 110 in the
warp direction 101, and fill yarns 120 in the fill direction 102.
As illustrated, the elastomeric 100 is a leano weave fabric, with
the warp yarns 110 crossing at various cross over points 105
between individual or groups of fill yarns 120 to secure the fill
yarns 120 in position. However, it is contemplated that the present
invention can be any type of weave necessary to form the
elastomeric fabric.
[0009] The warp yarn 110 comprises an elastomeric monofilament,
single component yarn. The warp yarn 110 can be an elliptical
cross-section with a major axis 113 and a minor axis 114. In one
embodiment, the ratio of major axis to minor axis of the warp yarn
is about 1.6. In one embodiment, the warp yarn 110 is a Riteflex or
Hytrel extruded and drawn copolyester yarn. In another embodiment,
the warp yarn can be a bicomponent elastomeric yarn, such as a
core/sheath yarn.
[0010] Elastomeric yarns, as used herein, means a nontextured yarn
that can be stretched at room temperature to at least twenty-five
percent (25%) over its original length and which after removal of
the tensile force will immediately and forcibly return to within
three percent (3%) of its original length. To determine if a yarn
is elastomeric, ASTM Standard Test Method for Permanent Deformation
of Elastomeric Yarns (D 3106-95a), which is incorporated herein in
its entirety by specific reference thereto, can be used with the
exception that the specimen is stretched to a length of 25% over
the original length of the specimen for all stretching time
periods, and the elongation after stretch is determined after the
longer relaxation time period.
[0011] The fill yarn 120 is a multicomponent air entangled, core
and effect yarn, made of five components. The first component is a
20 denier carbon impregnated yarn for static dissipation. The
second component is a 560 denier spandex yarn. The third, fourth,
and fifth components are 300 denier solution dyed textured
polyester yarns.
[0012] Although the present invention is illustrated as having only
the warp yarns 110 as elastomeric yarns, it is contemplated by the
present invention that the fill yarn 120 can be elastomeric and the
warp yarn 110 nonelastomeric, or both the warp yarn 110 and the
fill yarn 120 are elastomeric.
[0013] Referring now to FIGS. 4A and 4B, there is shown an enlarged
cross-sectional view of the warp yarns 110 of the elastomeric
fabric 100 at the point where the warp yarns 110 are not in
contact, and the cross over point 105, respectively, as shown in
FIG. 2. As previously discussed, various elastomeric warp yarns 110
cross over each other at the cross over points 105 to form the leno
weave.
[0014] Each of the elastomeric warp yarns 110 has an elliptical
cross section with the minor axis 113 generally orientated parallel
to the direction of the fabric thickness 103, and a major axis 114
generally orientated perpendicular to the minor axis 113. The cross
section of the warp yarn 110 shows it to have a smaller thickness
along the minor axis 113 at the cross over point 105 than at other
locations on the warp yarn 110. The result of the varying thickness
along the minor axis 113 of the warp yarn 110 is that the overall
thickness of elastomeric fabric 100 is about the same at the cross
over points 105 as other areas of the fabric 100. In one
embodiment, the thickness of the warp yarn 110 along the minor axis
113 at the cross over point 105 is from about 60% to about 82% of
the width of the warp yarn 110 along the major axis 114, and the
ratio of width in the major axis to the thickness in the minor axis
of the warp yarn is from about 1.8 to about 2.1.
[0015] The fabric 100 of the present invention can be formed by
weaving the elastomeric fabric with the warp yarns 110 and the fill
yarns 120 in the appropriate weave style, and calendaring the
fabric at room temperature. In one embodiment, a leno woven
elastomeric fabric or membrane in the construction illustrated
above, is formed according to the disclosure in U.S Pat. No.
6,035,901, titled "Woven Fabric Membrane For A Seating Surface",
issued to Stumpf et al. on Mar. 14, 2000, and which is incorporated
in its entirety herein by specific reference hereto. After the
leano elastomeric fabric or membrane is formed, it is calendered at
room temperature at about 650 PSIG, in one embodiment, and at about
1300 PSIG in another embodiment. In one embodiment, the nip rollers
calendering the fabric 100 are set to about 1550 pounds per linear
inch, and in another embodiment the nip rollers are set to about
3100 pounds per linear inch. The room temperature is controlled to
be between about 60 F. to about 100 F. In one embodiment, the
fabric is calendered at least 600 PSIG at the previously specified
room temperature. In one embodiment, the nip rollers calendering
the fabric 100 are set to about 1425 pounds per linear inch.
[0016] In one example, a leano weave was formed and calandered to
produce a fabric with 17% less thickness at the cross over point
105 than a fabric not calendered. The calendaring reduces the
thickness of the fabric at the cross over point 105 from about
0.0375 to about 0.031 inches.
[0017] The fabric of the above example was pre-stretched to about
5% in the warp direction and about 20% in the fill direction, and
subjected to a Martindale Abrasion Tests, as described in
ASTM-4966-98, which is incorporated herein in its entirety by
specific reference thereto. A control sample of the above example
was also subjected to the Martindale Abrasion Test prior to the
room temperature calendering of the fabric. The control sample was
also pre-stretched stretched to about 5% in the warp direction and
about 20% in the fill direction. Test specimens were used of 100%
Worsted Wool Flannel Fabric with 77 ends per inch and 67 picks per
inch, yarn size cotton warp of 19.13, yarn size system fill of
25.17, a weight of 5.26 ounces per square yard, which was take from
pants manufactured by Austin Reed. A failure of the test specimen
is defined as a hole appearing in the specimen, as discovered by
inspecting the specimen at every 2,000 cycles. It was found that
the control sample caused a failure of the test specimen at about
30000 cycles, and the example calendered at room temperature caused
a failure of the test specimen at about 40000 cycles.
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