U.S. patent application number 13/160504 was filed with the patent office on 2012-06-14 for elastomeric mesh fabric.
Invention is credited to Sava Cvek.
Application Number | 20120149263 13/160504 |
Document ID | / |
Family ID | 46199833 |
Filed Date | 2012-06-14 |
United States Patent
Application |
20120149263 |
Kind Code |
A1 |
Cvek; Sava |
June 14, 2012 |
Elastomeric Mesh Fabric
Abstract
An elastomeric mesh fabric with weft strands interwoven with
warp threads with the goal of imparting reduced wear on clothing
and other articles in contact therewith. Each warp thread has first
and second elastomeric helically wound strands, and the band-shaped
weft strands comprise a resilient yarn. The weft strands are
disposed in alternating first and second patterns that minimize
contact area between the weft strands and clothing and other
articles. Seat backs, seat bottoms, and other furniture components
can be formed by retaining the elastomeric mesh fabric relative to
frameworks.
Inventors: |
Cvek; Sava; (Jamaica Plain,
MA) |
Family ID: |
46199833 |
Appl. No.: |
13/160504 |
Filed: |
June 14, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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61354252 |
Jun 14, 2010 |
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Current U.S.
Class: |
442/2 |
Current CPC
Class: |
D03D 15/56 20210101;
Y10T 442/102 20150401; D03D 19/00 20130101; D10B 2505/08
20130101 |
Class at
Publication: |
442/2 |
International
Class: |
D04H 1/00 20060101
D04H001/00 |
Claims
1. An elastomeric mesh fabric comprising: warp threads; weft
strands interwoven with the warp threads; wherein each warp thread
comprises first and second elastomeric strands and wherein the weft
strands comprise a resilient yarn; and wherein, when the mesh
fabric is viewed in cross section, at least some of the weft
strands are disposed in a first pattern with a series of portions
that trough below the rightwardly disposed strand of each warp
thread, rise to a crest atop the leftwardly disposed strand of the
adjacent warp thread, and then fall in a downturned face that
passes between the leftward and rightward strands of that adjacent
warp thread.
2. The elastomeric mesh fabric of claim 1 wherein at least some of
the weft strands are disposed in a second pattern with a series of
portions that trough below the leftwardly disposed strand of each
warp thread, rise to a crest atop the rightwardly disposed strand
of the adjacent warp thread, and then fall in a downturned face
that passes between the leftward and rightward strands of that
adjacent warp thread.
3. The elastomeric mesh fabric of claim 2 wherein the first and
second patterns are disposed in alternation thereby contributing to
directional stability in the elastomeric mesh fabric.
4. The elastomeric mesh fabric of claim 2 wherein the first and
second strands of the warp threads are helically wound.
5. The elastomeric mesh fabric of claim 3 wherein the first and
second strands cross over one another once between each weft
strand.
6. The elastomeric mesh fabric of claim 5 wherein the first and
second patterns are disposed in alternation thereby contributing to
directional stability in the elastomeric mesh fabric.
7. The elastomeric mesh fabric of claim 1 wherein the weft strands
have a width and a thickness and wherein the width is greater than
the thickness such that the weft strands have a band shape.
8. A component of an article of furniture with an elastomeric mesh
fabric comprising: a framework; an elastomeric mesh fabric retained
relative to the framework wherein the elastomeric mesh fabric
comprises: warp threads; weft strands interwoven with the warp
threads; wherein each warp thread comprises first and second
elastomeric strands and wherein the weft strands comprise a
resilient yarn; and wherein, when the mesh fabric is viewed in
cross section, at least some of the weft strands are disposed in a
first pattern with a series of portions that trough below the
rightwardly disposed strand of each warp thread, rise to a crest
atop the leftwardly disposed strand of the adjacent warp thread,
and then fall in a downturned face that passes between the leftward
and rightward strands of that adjacent warp thread.
9. The component of the article of furniture of claim 8 wherein the
component comprises a seat back.
10. The component of the article of furniture of claim 8 wherein
the component comprises a seat bottom.
11. The component of the article of furniture of claim 8 wherein at
least some of the weft strands are disposed in a second pattern
with a series of portions that trough below the leftwardly disposed
strand of each warp thread, rise to a crest atop the rightwardly
disposed strand of the adjacent warp thread, and then fall in a
downturned face that passes between the leftward and rightward
strands of that adjacent warp thread.
12. The component of the article of furniture of claim 11 wherein
the first and second patterns are disposed in alternation thereby
contributing to directional stability in the elastomeric mesh
fabric.
13. The component of the article of furniture of claim 11 wherein
the first and second strands of the warp threads are helically
wound.
14. The component of the article of furniture of claim 12 wherein
the first and second strands cross over one another once between
each weft strand.
15. The component of the article of furniture of claim 14 wherein
the first and second patterns are disposed in alternation thereby
contributing to directional stability in the elastomeric mesh
fabric.
16. The component of the article of furniture of claim 8 wherein
the weft strands have a width and a thickness and wherein the width
is greater than the thickness such that the weft strands have a
band shape.
Description
FIELD OF THE INVENTION
[0001] The present invention relates generally to fabrics. More
particularly, disclosed herein is an elastomeric mesh fabric for
furniture and other applications intended to impart reduced wear on
articles, such as clothing worn by a furniture user, in contact
therewith.
BACKGROUND OF THE INVENTION
[0002] Resilient mesh has become an increasingly common fabric for
use in seating and other applications. In furniture applications,
the mesh is typically retained under tension by a peripheral
framework. Mesh retained in such a manner has been employed as the
sole support surface and in combination with subsidiary support
surfaces in back, seat, and other furniture components. The present
inventor has contributed to this art with a plurality of
inventions, including the Elastomeric Material Application System
disclosed in U.S. Pat. No. 6,996,895, the Methods and Arrangements
for Securing Fabric of U.S. Pat. No. 7,251,917, and Post-Assembly
Tension Adjustment in Elastomeric Material Applications as taught
by U.S. Pat. No. 7,517,024 with each of these being incorporated
herein by reference.
[0003] The use of resilient mesh in furniture support applications
has been found to be advantageous for a number of reasons. In
addition to the modern and clean appearance that mesh support
panels provide, mesh is advantageous for its breathability.
Resilient mesh also reduces zones of discomfort and excess
pressure. Moreover, resilient mesh can be retained and potentially
adjusted to have varied degrees of tension thereby to provide
varied degrees of support for different areas of a person's
body.
[0004] The structure of a typical prior art elastomeric mesh panel
is shown in FIGS. 1, 2A and 2B. The mesh panel, which is indicated
generally at 10, is a woven fabric formed by a series of warp
threads 12 interlaced with generally orthogonally disposed weft
strands 14. Each warp thread 12 is commonly formed by helically
wound first and second strands 12A and 12B, which are normally
formed from resilient elastomeric material. Each weft strand 14 is
normally formed from a resilient yarn, which can be wider than it
is thick thereby to have a band shape. As used herein, the term
yarn shall be held to mean a plied strand composed of fibers or
filaments. The warp threads 12 are separated by a distance a, and
the weft strands 14 are separated by a distance b.
[0005] The weft strand 14 in this prior art arrangement is woven
through the first and second strands 12A and 12B of each warp
thread 12 as shown in FIG. 2B. The mesh panel 10 can be considered
to have an occupant side facing the furniture user and the material
of the user's clothing and an opposite side facing away from the
occupant. The weft strand 14 is woven through the strands 12A and
12B to have flat portions alternatingly disposed to the occupant
side and then to the opposite side of the mesh panel 10. The flat
portions are generally coplanar with the mesh panel 10 when the
panel 10 is flat. Under this arrangement, flat portions M of the
weft strand 14 will face the furniture occupant and the material of
the occupant's clothing, and flat portions O will face away from
the furniture occupant.
[0006] Both ends of each flat portion M and O pass from the same
side of the mesh panel 10 between the strands 12A and 12B. With
this, depending on the side to which the flat portion M or O is
disposed, both ends of each flat portion M or O will either pass
from the material side to the opposite side or vice versa. Adjacent
weft strands 14 are identically configured but staggered so that
where one strand 14 has a flat portion M to the material side of
the panel 10 the adjacent strands 14 will have flat portions O to
the opposite side of the panel 10 and vice versa. Under this
configuration, aside from the portions passing between the strands
12A and 12B, roughly half of each weft strand 14 is disposed to the
material side of the panel 10.
[0007] While advantageous for multiple reasons, a significant
problem exhibited by resilient mesh has come to be recognized by
the present inventor, namely, that the structure of the elastomeric
mesh typical of the prior art undesirably acts as a mechanism for
pulling, chewing, and tearing fibers away from the occupant's
clothing. What is theorized is that the yarn forming the weft
strands 14, which stretch when pressure is applied thereto, act
much like tweezers to extract fibers from the occupant's clothing.
As the weft strands 14 are stretched, their constituent fibers
transform from being more generally unaligned and haphazardly
disposed to a greater degree of alignment thereby potentially
pinching and retaining fibers from the occupant's clothing.
Consequently, an expensive suit can become haggard and worn by
repeated exposure to mesh panels 10 so constructed.
[0008] This harm to the furniture user's clothing can readily be
appreciated by reference to the opposite side of a mesh support
surface chair that has been used for a significant period of time.
Having further reference to FIG. 3, for example, a mesh panel 10 is
retained in tension relative to a framework 100. There, fibers 102
that have been removed from the seat occupant's clothing have
accumulated on the opposite side of the mesh panel 10 giving a
clear indication of the wear and damage caused by the `chewing`
phenomenon exhibited by the mesh panel 10.
[0009] Advantageously, the present inventor has appreciated that
the large surface area in contact with the occupant's clothing and
the flat orientation of the weft strands 14 relative to the
occupant's clothing contribute to the pulling and tearing effect.
With the relatively large surface area of the flat portions M of
the weft strands 14 contacting the occupant's clothing, a greater
number of fibers are vulnerable to being ripped therefrom and a
more efficient `chewing` action is achieved. Based on this
appreciation and knowledge, the present inventor has discovered
that it would be advantageous to minimize the surface area of the
yarn or weft strands 14 that is in direct and flat contact with an
occupant's clothing while still exploiting the advantageous
characteristics that elastomeric mesh fabric can provide.
SUMMARY OF THE INVENTION
[0010] Accordingly, the present invention is founded on the basic
object of providing a mesh fabric that imparts less wear on
material in contact therewith.
[0011] An underlying object of the invention is to provide a mesh
fabric with yarn strands that exhibit reduced surface contact with
material in contact therewith.
[0012] These and further objects and advantages of the present
invention will become obvious not only to one who reviews the
present specification and drawings but also to those who have an
opportunity to experience an embodiment of the mesh fabric
disclosed herein. However, it will be appreciated that, although
the accomplishment of each of the foregoing objects in a single
embodiment of the invention may be possible and indeed preferred,
not all embodiments will seek or need to accomplish each and every
potential advantage and function. Nonetheless, all such embodiments
should be considered within the scope of the present invention.
[0013] In carrying forth these objects, an elastomeric mesh
according to the invention has weft strands interwoven with warp
threads with each warp thread comprising first and second
elastomeric strands and the weft strands comprising a resilient
yarn. When the mesh fabric is viewed in cross section, at least
some of the weft strands are disposed in a first pattern with a
series of portions that trough below the rightwardly disposed
strand of each warp thread, rise to a crest atop the leftwardly
disposed strand of the adjacent warp thread, and then fall in a
downturned face that passes between the leftward and rightward
strands of that adjacent warp thread. At least some of the weft
strands can be disposed in a second pattern with a series of
portions that trough below the leftwardly disposed strand of each
warp thread, rise to a crest atop the rightwardly disposed strand
of the adjacent warp thread, and then fall in a downturned face
that passes between the leftward and rightward strands of that
adjacent warp thread.
[0014] The first and second patterns can be disposed in alternation
to contribute to directional stability in the elastomeric mesh
fabric, and the first and second strands of the warp threads can be
helically wound. In one such embodiment, the first and second
strands can cross over one another once between each weft strand.
Moreover, the weft strands can have a width and a thickness with
the width being greater than the thickness such that the weft
strands have a band shape.
[0015] A component of an article of furniture can thus be formed
with an elastomeric mesh fabric as disclosed herein retained
relative to a framework. Many furniture and other components are
possible and within the scope of the present invention except as it
might be expressly limited. By way of example, the component of the
article of furniture can comprise a seat back, a seat bottom, or
some other portion of an article.
[0016] One will appreciate that the foregoing discussion broadly
outlines the more important goals and features of the invention to
enable a better understanding of the detailed description that
follows and to instill a better appreciation of the inventor's
contribution to the art. Before any particular embodiment or aspect
thereof is explained in detail, it must be made clear that the
following details of construction and illustrations of inventive
concepts are mere examples of the many possible manifestations of
the invention.
BRIEF DESCRIPTION OF DRAWINGS
[0017] In the accompanying drawing figures:
[0018] FIG. 1 is a view in front elevation of a panel of
elastomeric mesh under the prior art;
[0019] FIG. 2A is a magnified view in front elevation of a portion
of a panel of elastomeric mesh as taught by the prior art;
[0020] FIG. 2B is a cross-sectional view of the panel of
elastomeric mesh pursuant to the prior art of FIG. 2A taken along
the line 2B-2B;
[0021] FIG. 3 is a perspective view of a panel of prior art
elastomeric mesh applied to a seat back structure after a period of
use;
[0022] FIG. 4A is a magnified view in front elevation of a portion
of a panel of elastomeric mesh according to the present
invention;
[0023] FIGS. 4B and 4C are cross-sectional views of the panel of
elastomeric mesh of FIG. 4A taken along the lines 4B-4B and
4C-4C;
[0024] FIG. 5 is a perspective view of a panel of elastomeric mesh
applied to a seat back structure after a period of use depicting
the desired resultant benefits of the invention; and
[0025] FIG. 6 is a perspective view of panels of elastomeric mesh
applied to a seat back structure and a seat bottom structure.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0026] The mesh fabric disclosed herein is subject to a wide
variety of embodiments. However, to ensure that one skilled in the
art will be able to understand and, in appropriate cases, practice
the present invention, certain preferred embodiments of the broader
invention revealed herein are described below and shown in the
accompanying drawing figures. Therefore, before any particular
embodiment of the invention is explained in detail, it must be made
clear that the following details of construction and illustrations
of inventive concepts are mere examples of the many possible
manifestations of the elastomeric mesh taught herein.
[0027] Turning more particularly to the drawings, an elastomeric
mesh panel according to the present invention is indicated
generally at 10 in FIG. 4A and then in first and second cross
sections in FIGS. 4B and 4C. There, the elastomeric mesh 10 again
comprises a woven fabric formed by a series of warp threads 12
interwoven with generally perpendicularly disposed weft strands 14.
Each warp thread 12 is formed by helically wound first and second
strands 12A and 12B. The strands 12A and 12B can be formed from a
resilient material, such as an elastomer. Each strand 12A and 12B
can be formed as a single elastomeric strand or of multiple
elastomeric strands, which may or may not be interwoven. Each weft
strand 14 can be formed from a resilient yarn, which can be wider
than it is thick thereby to have a band shape. The warp threads 12
are again separated by a distance a, and the weft strands 14 are
again separated by a distance b.
[0028] The weft strand 14 is woven through the first and second
strands 12A and 12B of each warp thread 12 in the alternating
patterns shown in FIGS. 4B and 4C. In the first pattern as depicted
in FIG. 4B, the weft strand 14 is disposed in what may be
considered a rolling wave configuration in a first direction, which
is left to right in the drawing when the mesh panel 10 is viewed in
cross section, with a series of left-to-right inclined portions
that trough below the rightwardly disposed strand of each warp
thread 12, rise to a crest atop the leftwardly disposed strand of
the next warp thread 12, and then fall in a downturned face that
passes between the leftward and rightward strands of that next warp
thread 12.
[0029] In the second pattern as depicted in FIG. 4C, the weft
strand 14 is disposed in a rolling wave configuration in a second
direction, which is right to left in the drawing again when the
mesh panel 10 is viewed in cross section, with a series of
right-to-left inclined portions that trough below the leftwardly
disposed strand of each warp thread 12, rise to a crest atop the
rightwardly disposed strand of the next warp thread 12, and then
fall in a downturned face that passes between the leftward and
rightward strands of that next warp thread.
[0030] In this embodiment, the first and second strands 12A and 12B
of the warp threads 12 are helically wound with the strands 12A and
12B passing over one another once between each weft strand 14. As a
result, the first strand 12A will be the leftward strand in one row
of the weft strand 14, but it will be the rightward strand in the
adjacent row of the weft strand 14. The first and second patterns
are disposed in alternation to maintain directional stability in
the elastomeric mesh panel 10 and to ensure consistent performance
of the mesh panel 10.
[0031] Under this arrangement, it will be appreciated that,
although roughly half of the weft strand 14 will continue to face
the user of the furniture, the great majority of the weft strand 14
would tend to be spaced from direct contact with the furniture
occupant and the material of the furniture occupant's clothing.
Only the portions M will tend to be in a plane of direct contact
with the clothing of a furniture occupant or other contacting
material. The remaining portions of the weft strand 14 are angled
relative to and spaced from the opposed surfaces of the mesh panel
10. With this, the angled and spaced portions of the weft strand 14
will be less efficient in `chewing` fibers from a furniture
occupant's clothing or other material, and that material will tend
to exhibit less wear and damage through contact with the mesh panel
10.
[0032] As shown in FIG. 5, a mesh panel 10 according to the
invention retained relative to a framework 100 would ideally pull
and tear fewer fibers from the material of a user's clothing. As a
result, fewer fibers will be accumulated, and the clothing will
suffer less damage over time. As described in the present
inventor's U.S. Pat. No. 6,996,895, U.S. Pat. No. 7,251,917, and
U.S. Pat. No. 7,517,024, which are incorporated herein by
reference, the framework 100 and the retained mesh panel 10 could
take the form of a wide variety of furniture and other components.
By way of example as seen in FIG. 6, a framework 100 and a mesh
panel 10 could form a seat back 102, a seat bottom 104, or some
other component of an article of furniture.
[0033] With certain details and embodiments of a mesh fabric 10
according to the present invention disclosed, it will be
appreciated by one skilled in the art that changes and additions
could be made thereto without deviating from the spirit or scope of
the invention. This is particularly true when one bears in mind
that the presently preferred embodiments merely exemplify the
broader invention revealed herein. Accordingly, it will be clear
that those with certain major features of the invention in mind
could craft embodiments that incorporate those major features while
not incorporating all of the features included in the preferred
embodiments.
[0034] Therefore, the following claims are intended to define the
scope of protection to be afforded to the inventor. Those claims
shall be deemed to include equivalent constructions insofar as they
do not depart from the spirit and scope of the invention. It must
be further noted that a plurality of the following claims may
express certain elements as means for performing a specific
function, at times without the recital of structure or material. As
the law demands, these claims shall be construed to cover not only
the corresponding structure and material expressly described in
this specification but also all equivalents thereof that might be
now known or hereafter discovered.
* * * * *