U.S. patent application number 12/604574 was filed with the patent office on 2010-05-06 for moldable webbing.
This patent application is currently assigned to MURDOCK WEBBING COMPANY, INC.. Invention is credited to Robert E. Golz.
Application Number | 20100108176 12/604574 |
Document ID | / |
Family ID | 41394189 |
Filed Date | 2010-05-06 |
United States Patent
Application |
20100108176 |
Kind Code |
A1 |
Golz; Robert E. |
May 6, 2010 |
MOLDABLE WEBBING
Abstract
A woven fabric that is characterized by retaining its shape once
formed and that includes monofilament filling yarns that are
disposed in at least two separate plies, ground yarns that weave
alternatively over and under respective monofilament yarns, stuffer
yarns that extend in the direction between monofilament filling
yarns of respective plies and binder yarns that extend between
monofilament filling yarns of respective plies. Also disclosed is a
method of forming a woven fabric into a permanent shape.
Inventors: |
Golz; Robert E.; (Swansea,
MA) |
Correspondence
Address: |
SALTER & MICHAELSON;THE HERITAGE BUILDING
321 SOUTH MAIN STREET
PROVIDENCE
RI
029037128
US
|
Assignee: |
MURDOCK WEBBING COMPANY,
INC.
Central Falls
RI
|
Family ID: |
41394189 |
Appl. No.: |
12/604574 |
Filed: |
October 23, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11717539 |
Mar 13, 2007 |
7628180 |
|
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12604574 |
|
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60781851 |
Mar 13, 2006 |
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Current U.S.
Class: |
139/409 ;
156/148 |
Current CPC
Class: |
D10B 2321/022 20130101;
D10B 2331/04 20130101; D03D 15/00 20130101; D10B 2401/062 20130101;
D10B 2501/00 20130101; D10B 2331/02 20130101; D03D 11/00 20130101;
D03D 3/005 20130101; D03D 13/008 20130101 |
Class at
Publication: |
139/409 ;
156/148 |
International
Class: |
D03D 11/00 20060101
D03D011/00; D03D 23/00 20060101 D03D023/00 |
Claims
1. A woven fabric that is characterized by retaining its shape once
formed, said woven fabric comprising: mono-filament filling yarns
that are disposed in at least two separate plies; ground yarns that
weave alternatively over and under respective mono-filament filling
yarns; stuffer yarns that extend in a direction between
mono-filament filling yarns of respective plies; and binder yarns
that extend between mono-filament filling yarns of respective
plies.
2. The woven fabric of claim 1 wherein said mono-filament filling
yarns comprise a continuous single mono-filament.
3. The woven fabric of claim 1 wherein said mono-filament filling
yarns are selected from the group that includes nylon, polyester
and polypropylene.
4. The woven fabric of claim 1 wherein said mono-filament filling
yarn has a yarn size in a range between 14 and 10,000 denier.
5. The woven fabric of claim 1 wherein the density of said
mono-filament filling yarn is in a range of 5-100 yarns per
inch.
6. The woven fabric of claim 1 wherein said stuffer yarns are also
mono-filament yarns so as to enable shape retention in both warp
and weft directions.
7. The woven fabric of claim 1 wherein said mono-filament filling
yarns have a diameter of at least 0.002 inch.
8. The woven fabric of claim 1 wherein said ground yarns are a 20/2
spun polyester.
9. The woven fabric of claim 1 wherein said binder yarns are a 20/2
spun polyester.
10. The woven fabric of claim 1 wherein the density of said
monofilament filling yarn is in a range of 10-20 yarns per
inch.
11. A method of forming a woven fabric into a predetermined shape,
comprising the steps of: providing a woven fabric that includes a
mono-filament filling yarn that is disposed in separate plies;
weaving a ground yarn alternatively over and under respective
mono-filament filling yarns; forming the fabric into the
predetermined shape; and applying heat to the thus formed fabric at
a temperature of at least 150.degree. F. for at least 5
minutes.
12. The method of claim 11 including providing a monofilament
filling yarn of polypropylene and applying heat for at least 4
hours.
13. The method of claim 11 including providing a monofilament
filling yarn of nylon or polyester and applying heat to the thus
formed fabric at a temperature of at least 250.degree. F. for at
least 5 minutes.
14. The method of claim 11 including forming the fabric over a core
and applying the heat to permanently shape the fabric.
15. A woven single or multiple ply fabric comprising warp yarns,
binder yarns and monofilament filling yarns and that is moldable in
the filling direction.
16. The fabric of claim 15 wherein the range of denier of the
filling yarns is between 14 denier and 10,000 denier.
17. The fabric of claim 15 wherein the monofilament yarns are from
a class of manmade synthetic yarns.
18. The fabric of claim 15 wherein the warp yarns have a minimum
yarn size of 50,000 yards per pound.
19. The fabric of claim 15 wherein the binder yarns have a minimum
yarn size of 50,000 yards per pound.
20. The fabric of claim 15 wherein the picks across the width have
a range of 5 per linear inch to 100 per linear inch.
21. The fabric of claim 15 wherein the minimum density of the mono
filament filling yard is between 5 picks per linear inch using a
monofilament yarn having yarn size of 14 denier to 100 picks per
inch using a monofilament yarn having a yarn size of 10,000
denier.
22. The fabric of claim 15 wherein the warp yarns have a minimum
density of 144 ends per linear inch having a minimum yarn size of
50,000 yards per pound.
23. A fabric comprised of at least warp yarns and monofilament
filling yarns in at least two plies and wherein it has the
capability to be woven flat and subsequently molded in the filling
direction to retain its molded shape.
24. The fabric of claim 23 wherein it has the capability to be
unmolded into its original flat configuration.
25. The fabric of claim 23 wherein it has the capability to be
woven flat and subsequently molded into multiple folds in the
filling direction.
26. The fabric of claim 23 wherein molded in multiple folds in the
filling direction has the capability to be unmolded into its
original flat configuration.
27. The fabric of claim 23 wherein it has the capability to be
molded in the filling direction with one or multiple folds and to
retain the desired shape with the addition of heat.
28. The fabric of claim 27 wherein the exposure to a minimum range
of temperature of 250.degree. F. for 8 hours or 300.degree. F. for
5 minutes.
Description
RELATED CASES
[0001] Priority for this application is hereby claimed under 35
U.S.C. .sctn.119(e) to commonly owned and co-pending U.S.
Provisional Patent Application No. 60/781,851 which was filed on
Mar. 13, 2006 and which is incorporated by reference herein in its
entirety.
FIELD OF THE INVENTION
[0002] The present invention relates in general to an improved
webbing material, particularly one that can be molded or formed
into a predetermined shape and has a characteristic of being
retained in that shape. The present invention also pertains to a
method of forming a woven fabric so that it can be molded into a
permanent predetermined form or shape. The present invention is
considered as having a multitude of possible applications, such as
in the fall protection industry, for recreational products, in the
medical field, the apparel industry, for the military and possibly
for home land security applications.
BACKGROUND OF THE INVENTION
[0003] Narrow fabric webbing may be defined as any woven, braided
or knitted textile product that, in general, is less than 12 inches
in width, but may also be wider such as 18 inches in width. These
narrow fabric structures can be fabricated using spun textile yarns
made from natural fibers and or synthetically manufactured fibers
in continuous filament form.
[0004] Traditionally the majority of woven narrow fabric products
are comprised of the same class of fiber such as a 100% cotton
structure as used in the manufacture of belts for apparel or 100%
continuous filament polyester such as is used in automobile seat
belt applications. The selection of materials is based on the
particular requirements and end use of the finished product.
Generally, if a soft flexible finished narrow fabric product is
desired, spun or textured yarns are selected as the primary
substrate. Similarly, in a seat belt application low elongation,
high strength and a light weight fabric are desirable physical
properties, thus continuous filament polyester is a desirable
substrate. If thermal properties are desired the fiber choice may
be selected from the "aramid" class of synthetic fibers.
[0005] To further enhance the desired physical properties or hand
characteristics of a woven narrow fabric one must give equal
consideration to the type of weave and density of the fabric.
Typically woven narrow fabric weaves are selected but not limited
to the traditional class of weaves such a plain weave, twill weave,
satin weave, double plain weave, stuffer weaves, etc. Denser weave
constructions may be used to increase the breaking strength of a
woven narrow fabric.
[0006] Currently there are no narrow fabrics that are available on
the market using any of the above mentioned constructions,
densities or combination of yarns that allow woven narrow fabric
webbing to be formed so as to retain a selected shape. As a matter
of fact there is also no such fabric available whether for narrow
fabric applications or for wider fabric applications.
[0007] It is, therefore, very desirable and would have commercial
value to develop a narrow fabric webbing that is able to retain it
shape when formed. The present invention addresses this matter.
SUMMARY OF THE INVENTION
[0008] To accomplish the foregoing and other advantages the present
invention is embodied in a woven fabric that is characterized by
retaining its shape once formed. The woven fabric comprises
mono-filament filling yarns that are disposed in at least two
separate plies; ground yarns that weave alternatively over and
under respective mono-filament filling yarns; stuffer yarns that
extend in a direction between mono-filament filling yarns of
respective plies and binder yarns that extend between mono-filament
filling yarns of respective plies.
[0009] Other aspects of the present invention include the
mono-filament filling yarns may comprise a continuous single spun
mono-filament; mono-filament filling yarns are selected from the
group that includes nylon, polyester and polypropylene; the
mono-filament filling yarn may have a yarn size in a range between
14 and 10,000 denier; the density of the mono-filament filling yarn
may be in a range of 5-100 yarns per inch or more preferably 10-20
yarns per inch; the stuffer yarns are also mono-filament yarns so
as to enable shape retention in both warp and weft directions; the
mono-filament filling yarns may have a diameter of at least 0.002
inch; and ground and binder yarns may be a 20/2 spun polyester.
[0010] In accordance with another feature of the present invention
there is provided a method of forming a woven fabric into a
predetermined shape, comprising the steps of: providing a woven
fabric that includes a mono-filament filling yarn that is disposed
in separate plies; weaving a ground yarn alternatively over and
under respective mono-filament filling yarns; forming the fabric
into the predetermined shape; and applying heat to the thus formed
fabric at a temperature of at least 150.degree. F. for at least 5
minutes, but depending on the particular type of monofilament yarn
that is used.
[0011] In accordance with further aspects of the present invention
the monofilament yarns may be from a class of manmade synthetic
yarns; the warp yarns may have a minimum yarn size of 50,000 yards
per pound; the binder yarns may have a minimum yarn size of 50,000
yards per pound; the picks across the width may have a range of 5
per linear inch to 100 per linear inch; the minimum density of the
monofilament filling yarn may be between 5 picks per linear inch
using a monofilament yarn having a yarn size of 14 denier up to 100
picks per inch using a monofilament yarn having a yarn size of
10,000 denier; and the warp yarns may have a minimum density of 144
ends per inch having a minimum yarn size of 50,000 yards per
inch.
DESCRIPTION OF THE DRAWINGS
[0012] Numerous other features and advantages of the present
invention are realized upon a reading of the detailed description
that follows when taken in conjunction with the accompanying
drawings, in which:
[0013] FIGS. 1A-1G illustrate the ground weaves, stuffer yarns and
binder yarns as related to the mono-filament filling yarns used in
fabricating a fabric in accordance with the present invention;
[0014] FIG. 2 is a perspective view that illustrates the
relationship between the various yarns for a double plain weave
with 1 up 1 down binder and stuffers: and
[0015] FIG. 3 shows the same perspective view as in FIG. 2 but
illustrating the manner in which the ground yarns are able to slide
over the mono-filament yarns to retain fabric shape.
DETAILED DESCRIPTION
[0016] The fabric of the present invention is capable of retaining
its shape when it is molded into virtually any shape or
configuration. The fabric may be formed around an object or series
of objects in order to define a particular shape. For example, the
fabric may be pre-formed by hand into an "S" or "L" configuration
for such applications where multiple shapes are desired. A heat
cycle may be used to maintain the molded fabric into a more or less
permanent form.
[0017] Narrow and other fabrics are manufactured using various
weave configurations. Weave configurations used in the fabric
industry are comprised of, but not limited to the following types
of weaves.
Plain weave 3 up 1 down twill 3 up 1 down 1 up 3 down twill Plain
tubular weave 2 up 2 down tubular weave 3 up 1 down tubular weave 5
up 1 down 1 up 5 down with or without binder yarns 7 up 1 down 1 up
7 down with or without binder yarns Double plain weave with 1 up 1
down binder sequence Double plain weave with 2 up 2 down binder
sequence Double plain weave with 1 up 1 down binder and stuffers
Double plain weave with 2 up 2 down binder and stuffers
Self-interlocking 12 pick repeat Self-interlocking 14 pick repeat
Three ply--face middle back with 3 up 3 down binders Three
ply--face middle back with 2 up 2 down binders Double wall tubular
with connected edges Slotted weave 2 up 1 down 1 up 2 down twill
with binders and stuffers 4 ply plain weave 4 ply
self-interlocking
[0018] The above weave configurations may consist of yarns of
various sizes and types. There are yarns that weave in the length
wise direction, parallel to the edges and a yarn or yarns which
weave across the width of the webbing from edge to edge. The yarns
that weave in the length wise direction are usually referred to as
warp or ground yarns and the yarns which weave across the width of
the webbing are referred to as filling yarns, weft yarn or
picks.
[0019] The present invention is based, in one embodiment thereof,
on the webbing being able to be folded in the filling direction,
such as that illustrated in FIG. 3 herein. The density of a narrow
fabric is determined by the number and size of warp and filling
ends per given length of webbing. Denser webbing has been found to
have better ability to retain its shape when folded than webbing
that is less dense. However, to provide shape retention it has been
found in accordance with the present invention that a mono-filament
fiber is to be used for the filling yarns. Alternatively, if the
bending is desired in the orthogonal direction then the ground or
stuffer yarns are mono-filament.
[0020] Thus, in a preferred embodiment the present invention is
directed to a webbing that uses a mono-filament yarn in the filling
direction. The mono-filament yarn is a single filament of a
manufactured fiber, usually of a denier of at least 14. Instead of
a group of filaments being extruded through a spinneret to form a
yarn, mono-filaments are generally extruded individually. The
mono-filament yarn may come from the class of manufactured fibers
of nylon, polyester, polypropylene or any such fiber than exhibits
the characteristics to allow the webbing to be molded.
[0021] The principles behind a narrow fabric being able to be
molded are basically two fold. The first being the use of a
mono-filament filling yarn and the second is the density of the
fabric itself, particularly the density of the pick count. The
preferred weave design for this invention is a double plain weave
with 1 up 1 down binder and stuffers. However, any one of the
previously listed weaves or other weaves may be used in practicing
the principles of the present invention. A mono-filament yarn has
greater stiffness than a multifilament yarn of equal size. In this
preferred weave design the filling yarn (weaves from edge to edge)
is inserted by either a weft needle as in a needle loom or by a
shuttle as would be used in a shuttle type loom. The loom is
programmed so as to insert the first filling yarn (pick) 10 on the
bottom ply of the 2 ply weave. The next filling yarn 10 is inserted
on the top ply of the 2 ply weave. The filling yarn alternates from
bottom to top for each pick. Numbering the sequence of picks, as
illustrated in FIGS. 1A-1G, shows all the odd numbered picks lie on
the back of the webbing and all the even numbered picks lie on the
face of the webbing, or visa versa if the first filling yarn is
inserted on the face of the webbing. See FIG. 1A to 1D and the
numbered picks 1-24.
[0022] One half of the ground ends 12 weave on the top ply of the
webbing and the other half weave on the bottom ply of the webbing.
The stuffer yarns 14 weave under the filling yarns 10 that weave on
the top ply and over the filling yarns that weave on the bottom
ply. Lastly, the binder yarns 16 have a 1 up 1 down weave
configuration as shown in FIG. 1E. These binder yarns 16 lock the
double plain 2 ply construction together and contribute to the
retention feature of the present invention. This weaving sequence
includes first weaving under filling yarn number "1" and over
filling yarn number "2", under "3", over "4" and so on. This binds
all the components together. Refer to FIG. 1.
[0023] The preferred embodiment for the ground and binder yarns is
a 20/2 spun polyester. Since the stuffer yarns 14 do not actually
weave, they just lie between the top and bottom ply, the preferred
embodiment for the yarns 14 can be either spun polyester or
continuous filament yarns. Lastly, the mono-filament filling yarn
10 preferred embodiment has a yarn size between 14 denier and
10,000 denier.
[0024] It is theorized that the reason this invention has moldable
properties is because of the propensity of the ground yarns to be
able to slide over the mono-filament filling yarns. This occurs
when the fabric is bent in the filling direction, such a shown in
FIG. 3 at 20. Although the ground ends slide over the filling yarns
when bent in the filling direction, there is not enough recovery
forces in the filling yarns to allow the ground ends to slip back
into their original position, thus the webbing keeps its shape. By
making the construction denser, particularly the density of the
filling yarns, the moldability is increased. The fabric retains its
shape until a force that exceeds the bending force of the filling
yarn is applied to the fabric. When a force that exceeds the
bending force of the mono-filament filling yarn is applied to the
fabric, the ground yarns return to their original position and the
fabric returns to its original shape. The mono-filament filling
yarn 10 because of its high stiffness properties lies flat and
straight across the width of the fabric allowing for slippage of
the ground ends 12. The filling yarn does not weave around the
ground ends in the weaving operation, the ground ends weave around
the filling yarns. See FIGS. 2 and 3.
[0025] It is also possible to use the same theory to mold the
webbing in the opposite direction. The principal is that the
non-mono-filament yarns be able to slide over the mono-filament
yarns. To have moldable properties in the warp direction one would
change the stuffer yarn type from spun or continuous filament to
the stiffer mono-filament yarns. Density would again play an
important role. A denser mono-filament construction for the stuffer
weave, the stiffer and more moldable the fabric is in the warp
direction. Combinations of densities in both stuffer and filling
directions allows a fabric to be built that possesses more moldable
characteristics in the filling and less in the warp direction or
better moldable properties in the warp direction and less in the
filling direction. The possibilities are limitless depending on the
end item use.
[0026] Trials have been performed on a Murdock Webbing Part Number
1198, 5-1/2'' webbing varying the ambient temperatures to see how
and what physical properties might be influenced. The first trial
was to subject the webbing to 150.degree. F. temperatures for a
couple of hours. The webbing with polyester monofilament filling
did not loose its moldable properties while at 150.degree. F. When
brought back to room temperature the product retained all of its
original physical and moldable properties.
[0027] Heat on the other hand has quite a different effect on the
product. A great deal of textile products are woven with natural
yarns and then exposed to a secondary process to affix the color.
These processes normally expose the webbing to some type of
dyestuff in an aqueous solution, then dried at elevated
temperatures between 200-325.degree. F. for varying amounts of
time.
[0028] The trials that were conducted showed that all moldable
properties were lost when the webbing was exposed to temperatures
in the 225.degree. F. range or higher. Thus, if color is to be
added to this moldable webbing during the fabrication process, one
has to use pre-dyed yarns or air dry the product at ambient
temperature.
[0029] Additional trials were run to find out at what point on the
temperature line did the webbing began to loose its moldable
properties. The first trial was to expose the product to
temperatures of 150 to 200.degree. F. at 10 degree increments for
one hour. Under these conditions the webbing did not loose
moldability. However at 200.degree. F. for 8 hours the webbing did
loose substantially all of its moldability.
[0030] Another trial was run to see if heat could be used to
permanently mold the fabric product. In one test using nylon or
polyester filler yarns the moldable webbing was wrapped around an
object, tied in place and the core and webbing was exposed to
250.degree. F. for at least 5 minutes. When the core was removed
the webbing retained the shape of the core and could not be brought
back to its original flat shape. In another example, using
polypropylene for the filler yarns it was found that the product
could be permanently molded by the application of a temperature of
at least a 150.degree. F. for at least 5 minutes. In either of the
above examples, it is preferred that the subjected temperatures be
exposed for greater than 5 minutes, perhaps as long as 4-8
hours.
Samples of a 2 inch wide narrow fabric were made using the
following construction: Weave: Double Plain with 1 up and 1 down
binder sequence Ground ends: 288 ends 20/2 spun polyester Binder
ends 35 ends 20/2 spun polyester Stuffer ends 170 ends 1000/2
continuous filament polyester Stuffer ends 72 ends 2150 denier
mono-filament polyester Filling Yarn 17.5 picks of 2150 denier
monofilament polyester filling (2 picks per shed).
[0031] The density of the filling yarn was calculated. The formula
used was the total picks per inch times the denier of the filling
yarn is:
17.5 picks per inch.times.2 picks per shed.times.2150 denier=75,250
total denier.
[0032] A method was developed to determine the force required to
bend this webbing in the filling direction. The test involved
taking the 2'' wide sample, placing it in a set of 3'' wide flat
faced clamps in a vertical position and clamping it in position
with 11/2'' exposed over the top of the clamp. Next the 3'' of
webbing was bent in the filling direction at a 15 degree angle from
vertical. The load was applied from the top clamp compressing the
webbing in the bottom clamp with a speed of 1 inch per minute. The
load was recorded when the top clamp compressed the webbing in the
bottom clamp by 1 inch.
[0033] Additional samples were made reducing the pick count
(density) of the filling yarn and the same test method applied to
the less dense webbing to show the effect of density on the force
required to bend or mold the webbing in the filling direction. The
table below illustrated the relationship between filling density
and bending force. [0034] Trial #1 17.5 picks per inch 2150
filling=75,250 total denier=9.86 pounds force at a 1'' deflection.
[0035] Trial #2 16.0 picks per inch 2150 filling=68,800 total
denier=7.50 pounds force at a 1'' deflection. [0036] Trial #3 14.0
picks per inch 2150 filling=60,200 total denier=5.69 pounds force
at a 1'' deflection. [0037] Trial #4 12.0 picks per inch 2150
filling=51,600 total denier=3.67 pounds force at a 1'' deflection.
[0038] Trial #5 10.0 picks per inch 2150 filling=43,000 total
denier=1.54 pounds force at a 1'' deflection.
[0039] The same type testing was done on the above sample but in
the warp direction. The construction of the webbing is the same as
in trial #5 with the exception of the addition of the mono-filament
stuffer ends. The first sample used 72 ends of 2150 denier and the
second sample used 36 ends of 2150 denier. The test was done the
same way with the warp yarn in the vertical direction at a 15
degree angle. The bending force in the warp direction is listed
below: [0040] Sample #1 72 ends per inch 2150 stuffer=154,800 total
denier=2.82 pounds force at a 1'' deflection. [0041] Sample #2 36
ends per inch 2150 stuffer=77,400 total denier=1.42 pounds force at
a 1'' deflection.
[0042] The woven fabric of the present invention is thus
characterized by a number of factors that enable this moldability.
First is the use of a mono-filament yarn in the filling direction.
If moldability is desired in the warp direction there are to be
mono-filament yarns in the stuffer weave. Second is the density of
the fabric, particularly in the filling direction. This preferably
is at least 14 denier and is preferably in a range of 14-10,000
denier. It is also preferred that the fabric be constructed in a
dual ply arrangement. For the product to permanently keep its
shape, when using nylon or polyester, it is to be exposed to a
minimum temperature of 250.degree. F. for at least 5 minutes and
preferably more than that even up to 8 hours when using a 2150
polyester monofilament yarn for filling.
[0043] Having now described a limited number of embodiment of the
present invention, it should now be apparent to those skilled in
the art that numerous other embodiments and modifications thereof
are contemplated as falling within the scope of the present
invention as represented by the appended claims.
* * * * *