Stretchable Outdoor Cover Product

Abstract

An outdoor cover product is disclosed. The outdoor cover product is water resistant and breathable. The product is made from a woven fabric that has excellent stretch properties in multiple directions.

Claims

1. An outdoor cover product comprising: a cover having an interior surface and an exterior surface, the cover having a shape adapted to cover an outdoor structure, the exterior surface of the cover having a UV rating of at least 800 hours and having a spray rating of at least 90, the cover comprising a woven fabric comprised of multifilament yarns, the multifilament yarns comprising texturized yarns, the texturized yarns having greater than about 80 tie downs per meter, the woven fabric having a warp direction and a fill direction, the multifilament yarns extending in both the warp direction and the fill direction, the fabric having a stretch of at least 8% in the warp direction and a stretch of at least 8% in the fill direction when tested according to ASTM Test D3107 at a load of 4 lbs.

2. An outdoor cover product as defined in claim 1, wherein the texturized yarns have greater than about 90 tie downs per meter and have less than about 175 tie downs per meter.

3. An outdoor cover product as defined in claim 1, wherein the multifilament yarns have a denier of from about 50 to about 800.

4. An outdoor cover product as defined in claim 1, wherein the multifilament yarns have a denier of from about 250 to about 350.

5. An outdoor cover product as defined in claim 1, wherein the multifilament yarns extending in the warp direction have a denier of from about 250 to about 350 and wherein the multifilament yarns extending in the fill direction have a denier of from about 350 to about 650.

6. An outdoor cover product as defined in claim 1, wherein the woven fabric contains from about 50 yarns to about 70 yarns per inch in the warp direction and contains from about 30 yarns to about 45 yarns per inch in the fill direction.

7. An outdoor cover product as defined in claim 1, wherein the woven fabric has a stretch of at least 10% in the warp direction and a stretch of at least 10% in the fill direction.

8. An outdoor cover product as defined in claim 1, wherein the woven fabric has a stretch of at least 15% in the fill direction,

9. An outdoor cover product as defined in claim 1, wherein the multifilament yarns are solution dyed.

10. An outdoor cover product as defined in claim 1, wherein the fabric is impregnated with a water resistant finish.

11. An outdoor cover product as defined in claim 10, wherein the fabric is impregnated with a flame retardant composition.

12. An outdoor cover product as defined in claim 1, wherein the fabric is non-coated and is not laminated to any other fabric or film layers.

13. An outdoor cover product as defined in claim 1, wherein the multifilament yarns contained in the fabric contain polyester filaments and the polyester filaments comprise at least 80% by weight of the fabric.

14. An outdoor cover product as defined in claim 1, wherein the fabric has a basis weight of from about 4.5 osy to about 9.5 osy.

15. An outdoor cover product as defined in claim 1, wherein the fabric has a hydrostatic pressure when tested according to AATCC 127 of from about 11 cm to about 15 cm.

16. An outdoor cover product as defined in claim 1, wherein the product comprises a boat cover.

17. A shade structure as defined in claim 1, wherein the product is attached in 3 locations or more to the structure.

18. An umbrella comprising a frame, the frame being covered by the outdoor cover product of claim 1.

19. An outdoor cover product as defined in claim 1, wherein the product comprises a furniture cover.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0037] A full and enabling disclosure of the present disclosure, including the best mode thereof to one of ordinary skill in the art, is set forth more particularly in the specification, including reference to the accompanying Figures in which:

[0038] FIG. 1 represents a shade structure in accordance with one embodiment of the present disclosure;

[0039] FIG. 2 represents another embodiment of a shade structure in accordance with the present disclosure;

[0040] FIG. 3 represents an umbrella in accordance with one embodiment of the present disclosure; and

[0041] FIG. 4 represents a piece of outdoor furniture in accordance with one embodiment of the present disclosure.

[0042] Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the present invention.

DETAILED DESCRIPTION

[0043] It is to be understood by one of ordinary skill in the art that the present discussion is a description of exemplary embodiments only, and is not intended as limiting the broader aspects of the present disclosure, which broader aspects are embodied in the exemplary construction.

[0044] In general, the present disclosure is directed to an outdoor cover product and fabric suitable for outdoor applications that may have, UV resistant properties, and/or fire resistant properties. In accordance with the present disclosure, the outdoor cover product also has excellent stretch properties. In one embodiment, for instance, the outdoor cover product can be made with a fabric that has excellent stretch characteristics in at least two different directions, such as orthogonal directions. In addition to being stretchable, the woven fabric of the present disclosure also has excellent light blocking properties. For example, the woven fabric can be made in order to block a substantial amount of light, in addition, the fabric can be constructed so that no openings or pinholes are formed allowing for very uniform light blocking characteristics. In addition, the woven fabric has excellent resistance to the penetration of liquids. For example, the woven fabric of the present disclosure can have excellent resistance properties to the penetration of water under hydrostatic pressure without the mark off typical of those coated and noncoated fabrics.

[0045] Producing an outdoor fabric with multi-directional stretch properties provides numerous benefits and advantages. For instance, in the past, outdoor fabrics were purposefully made to have dimensional stability and therefore no stretch properties. Thus, significant problems were encountered in attempting to fit the fabrics on complex patterns or forms. The outdoor cover product of the present disclosure, however, has stretch properties that allow the fabric when placed over a 3-dimensional article or object to have form-fitting properties. Not only can the fabric conform to the shape of an object or article, but the fabric allows for easier placement over such articles or structures. Because the fabric of the present disclosure has stretch properties in multiple directions, the fabric is soft and pliable while still retaining excellent tear properties. The outdoor cover product also protects from other outdoor elements such as visible light, infra-red heat, heat, organic particles, pollution residuals, bird droppings, and the like.

[0046] In order for the fabric of the present disclosure to be strong and tear resistant, the fabric can be made from multifilament yams. The multifilament yarns can provide greatly improved abrasion resistance. The multifilament yarns can be solution dyed and enhanced with UV stabilizers so that the yarns and the fabric can have greatly improved UV resistance. In this regard, UV stabilizers can include UV absorbers and the like. The chemical composition can also maintain air permeability. Finally, the chemical composition allows for fire resistant capability.

[0047] Fabrics that are suitable for use in the process of the present disclosure may be manufactured with yarns made from inelastic polymer filaments, such as polyamide (nylon), polyester, polypropylene, polytetrafluoroethylene, polyethylene, mixtures thereof, and other similar yarns. For many applications, polyester and/or polyamide filaments are used to construct the yarns. In one exemplary embodiment, SATURA yarns are utilized which are commercially available from Unifi, Inc. The SATURA yarns are solution dyed with specialty pigments commercially available from American Colors. In addition, UV stabilizers are added to the yarns. In a solution dyed yarn, pigments and UV stabilizers are added while the yarn is still in a liquid state. In some embodiments, the UV stabilizer utilized is SATURAMAX UV absorber which is commercially available from Unifi, Inc. The components become part of the fibers and resist fading or washing out.

[0048] It has also been found that UV resistance can be greatly increased using such yarns. In some embodiments, the UV rating of the fabrics is at least 500 hours. In some embodiments, the UV rating of the fabrics is from about 500 hours to about 1500 hours. In some embodiments, the UV rating of the fabrics is at least 800 hours. In still other embodiments, the UV rating of the fabrics is at least 1000 hours. In some embodiments, the UV rating of the fabrics is from about 800 hours to about 1500 hours. In some embodiments, the UV rating of the fabrics is from about 1000 hours to about 1200 hours. High UV resistance characteristics in fabrics are important for color and strength retention.

[0049] The yarns used in the fabric of the present disclosure may be woven into various constructions. A particular weave may be selected to provide durability, breathability, and ease of fabrication. In accordance with the present disclosure, the yarns are woven into a fabric that has multidirectional stretch properties. Any suitable weave can be used to construct the fabric, such as a plain weave, a twill weave, a rip stop weave, a herringbone weave, or the like.

[0050] In order to incorporate stretch into the woven fabric, in one embodiment, the fabric is constructed from textured yarn that can include a significant amount of crimps or tie downs. The fabric can be woven with a relatively loose weave and then subjected to a shrinking process that shrinks the fabric in at least one direction, such as in both directions, and tightens the weave providing the fabric with greater dimensional stability. The fabric is then dried in a somewhat relaxed state that results in a fabric having stretch characteristics in at least one direction, such as in both directions.

[0051] For example, woven fabrics made according to the present disclosure can have a stretch of at least about 8% in the warp direction and a stretch of at least about 8% in the fill direction. Stretch can be measured according to ASTM Test 03107 at a load of 4 lbs. Of particular advantage, woven fabrics made according to the present disclosure can have the above stretch properties while being constructed only of inelastic multifilament yarns. For example, the fabric of the present disclosure can have multidirectional stretch properties without containing elastic yarn such as spandex.

[0052] In one embodiment, the woven fabric can have a stretch in the warp direction and in the fill direction of greater than about 9%, such as greater than about 10%, such as greater than about 11%. In one embodiment, the fabric can have greater stretch in the fill or weft direction than in the warp direction. For instance, stretch in the warp direction can be from about 6% to about 15% while stretch in the fill direction can be from about 15% to about 25%. In one embodiment, the woven fabric can have from about 8% to about 13% stretch in the warp direction and from about 17% to about 22% stretch in the fill direction.

[0053] The weight of the fabric made in accordance with the present disclosure can vary and generally will depend upon the particular application for which the fabric is used. The fabric is designed to withstand inconsistent and repetitive loads with high dynamic forces like wind gusts, heavy rain, air pressure, and the like. In general, the fabric can have a basis weight of from about 3 osy to about 20 osy. For applications where lighter fabrics are desired, the basis weight can be from about 4.5 osy to about 9.5 osy, such as from about 6 osy to about 7.5 osy. When heavier fabrics are needed, however, the basis weight can be from about 8 osy to about 15 osy, such as from about 10 osy to about 13 osy.

[0054] In general, the yarns used to construct the fabric are multifilament yarns, although it is believed that monofilament yarns may be used in some applications. In one embodiment, the fabric is made exclusively from inelastic multifilament yarns and does not contain any spun yarns. In one embodiment, the yarns can be made exclusively from polyester or nylon. The denier of the yarns again will vary depending upon the type of product being formed with the fabric. In general, however, the denier of the yarns can be from about 50 to about 900. In one embodiment, the denier of the multifilament yarns may be about 800 or less, such as about 600 or less, such as about 300 or less. In one embodiment, the multifilament yarns can have a denier of from about 250 denier to about 350. In an alternative embodiment, the multifilament yarns may have a denier of from about 400 to about 650. For fabrics having a lower basis weight, the denier of the multifilament yarns can be from about 50 to about 250, such as from about 100 to about 200.

[0055] In one embodiment, the denier of the multifilament yarns in the warp direction can be different than the denier of the multifilament yarns in the fill direction. For example, in one embodiment, the denier of the yarns in one direction can be less than the denier of the yarns in a perpendicular direction. In one embodiment, for instance, the multifilament yarns can have a denier in one direction of from about 250 to about 350 and can have a denier in a perpendicular direction of from about 350 to about 650. For example, in one particular embodiment, the warp yarns can have a denier of from about 250 to about 350 while the fill yarns can have a denier of from about 350 to about 650.

[0056] As described above, the multifilament yarns of the present disclosure can be highly texturized. Incorporating highly texturized yarns into the fabric and then subjecting the fabric to a bulk or relaxed shrinking process can incorporate significant stretch characteristics into the fabric while also providing the fabric with better dimensional stability properties. Texturized yarns can include crimps or tie downs. For example, multifilament yarns incorporated into the woven fabric of the present disclosure can have greater than about 50 tie downs per meter, such as greater than about 60 tie downs per meter, such as greater than about 70 tie downs per meter, such as greater than about 80 tie downs per meter, such as greater than about 90 tie downs per meter. The yarns generally have less than about 200 tie downs per meter, such as less than about 175 tie downs per meter, such as less than about 150 tie downs per meter. In one embodiment, the yarns have from about 85 tie downs per meter to about 130 tie downs per meter, such as from about 90 tie downs per meter to about 125 tie downs per meter. Tie downs are also referred to as nodes or tats. Tie downs per meter can be measured using a FIBRESCAN LABTEX machine sold commercially by Saurer Fibrevision.

[0057] In addition to various other parameters, the yarn density of the fabric made in accordance with the present disclosure can also vary depending upon numerous factors. The yarn density in the warp direction, for instance, can generally be greater than about 40 yarns per inch, such as greater than about 45 yarns per inch, such as greater than about 50 yarns per inch, such as greater than about 55 yarns per inch. The yarn density in the warp direction is generally less than about 70 yarns per inch, such as less than about 60 yarns per inch. In the fill direction, the yarn density is generally greater than about 25 yarns per inch, such as greater than about 30 yarns per inch, such as greater than about 35 yarns per inch, such as greater than about 40 yarns per inch. The yarn density in the fill direction is generally less than about 70 yarns per inch, such as less than about 60 yarns per inch, such as less than about 55 yarns per inch.

[0058] In one embodiment, the fabric can be treated with a chemical composition, such as a composition that improves the water resistant properties of the fabric. In accordance with the present disclosure, the water resistant composition is impregnated into the yarns and does not form a film over one surface of the fabric. Thus, the fabric can be treated with a water resistant composition in accordance with the present disclosure while still remaining a non-coated fabric. In this manner, the fabric can have excellent water resistant properties while still remaining breathable and stretchable. The water resistant finish can also improve the abrasion resistant properties of the fabric.

[0059] In one embodiment of the present disclosure, the chemical composition is made from a solution of a fluorocarbon polymer that is applied to the fabric. For example, the chemical composition can be made from SHELL TEC 6 which is commercially available from Bolger & Oil-learn Inc. In one embodiment, the fluorocarbon polymer can comprise a C6 to C8 fluorocarbon. Fluorocarbon polymer solutions are also commercially available from other numerous sources and suitable for use herein.

[0060] Besides containing a fluorocarbon polymer, the chemical composition can also contain various other additives.

[0061] For instance, in one embodiment, the chemical composition can include a water repellent agent. In some embodiments, Phobotex JVA, commercially available from Huntsman International, LLC as an emulsion of paraffin wax and melamine resin, is utilized as a suitable water repellent agent. Other commercially available water repellent agents are also available from other sources and are suitable for use herein.

[0062] In addition, the chemical composition can also include an extender to promote durability. In some embodiments, a blocked isocyanate extender can be utilized. In some embodiments, the blocked isocyanate extender is added after copolymerization (i.e., as a blended isocyanate). An example of a suitable blocked isocyanate is HYDROPHOBOL XAN available from Huntsman International, LLC. In accordance with the present disclosure, it has been determined that a blocked isocyanate extender can be beneficially combined with a paraffin wax and melamine resin water repellent agent to impart desirable characteristics to the non-coated fabric described herein. Other commercially available blocked isocyanates are also suitable for use herein.

[0063] In one embodiment of the present disclosure, the chemical composition can include a flame retardant composition. The flame retardant can be selected from a variety of suitable flame retardant compounds including phosphorous compounds, such as cyclic phosphonates. An example of a suitable flame retardant is PYROVATEX SVC which is commercially available from Huntsman International, LLC. However, any other suitable flame retardant compounds may also be utilized. The flame retardant compound serves to make the fabric fire resistant. A fire resistant fabric is noncombustible and nonconductive and can be utilized where flammability is a concern.

[0064] In this regard, a difficulty in achieving fire resistance with non-coated fabrics while maintaining suitable water resistance performance is that the fire resistance components typically do not permit a fluorocarbon polymer to satisfactorily bond with the fabric in comparison. As described above, paraffin wax and melamine resin water repellent agent components can assist to fill in the fabric pores to help resist water pressure. Still, because some fluorocarbon polymers can have a tendency to burn, the weight percentages of fluorocarbon polymer and fire resistant agent as described herein are controlled in maintaining the fire resistance of the fabric.

[0065] Additionally, the chemical composition can contain an antimicrobial agent. The antimicrobial agent serves to help make the fabric mildew resistant. Any suitable antimicrobial agents known in the art can be utilized. In some embodiments, the chemical composition can contain a wetting agent such as isopropyl alcohol.

[0066] In one embodiment, the chemical composition can contain from about 1 percent to about 20 percent by weight of a fluorocarbon polymer composition, and particularly from about 2 percent to about 10 percent by weight of the bath. The chemical composition can contain from about 0.1 percent to about 10 percent by weight of water repellent agent and more particularly from about 2 percent to about 5 percent by weight. The chemical composition can contain from about 0.1 percent to about 5 percent by weight of extender and more particularly from about 1 percent to about 3 percent by weight. The chemical composition can contain from about 1 percent to about 20 percent by weight of fire resistant agent and more particularly from about 5 percent to about 15 percent by weight. Further, the chemical composition can contain an antimicrobial and a wetting agent in an amount from about 0.1 percent to about 5 percent by weight, and particularly from about 0.1 percent to about 1 percent by weight of the bath,

[0067] In order to produce a liquid resistant fabric in accordance with the present disclosure, the fabric is first constructed. In one embodiment for instance, the fabric is woven with a relatively loose weave using highly textured multifilament yarns. After the fabric is woven, the fabric is subjected to a shrinking process, which shrinks the fabric in both the warp direction and the fill direction. The use of highly texturized yarns in conjunction with controlled shrinkage of the fabric results in a fabric having excellent stretch properties while still remaining dimensionally stable.

[0068] Various different techniques can be used in order to shrink the fabric. For example, in one embodiment, the fabric can be exposed to higher temperatures in a relaxed state that causes the fabric to shrink.

[0069] In one embodiment, for instance, the fabric is exposed to heat and optionally pressure by contacting the fabric with a hot aqueous solution, such as water, in a pressurized vessel. For example, in one embodiment, the fabric can be fed through a jet dye machine in a relaxed state and exposed to water at a relatively high temperature. The temperature of the water, for instance, can be above about 180 F., such as above about 200 F., such as above about 210 F., such as above about 220 F., such as above about 230 F. The temperature of the water is generally below about 300 F. The water can be in the form of steam or can be in a liquid state. When in a liquid state, the fabric can be contained in a pressurized vessel when the temperature of the water is above 220 F.

[0070] In one particular embodiment, the woven fabric is fed through a jet dye machine that includes a nozzle for dispensing water at a temperature above 220 F. The fabric is circulated within the jet dye machine for about 1 to about 3 hours which causes the relaxed fabric to shrink in both the warp direction and the fill direction. For instance, the fabric can shrink at least 10% in both the warp direction and the fill direction, such as at least about 13%, such as at least about 15%, such as at least about 18%, such as at least about 20%, such as at least about 25%, and generally less than about 40% in both the warp direction and the fill direction.

[0071] After being subjected to a shrinking process, the woven fabric is dried. In general, the fabric can be dried in a relatively relaxed state in order to maintain the stretch properties. In one embodiment, for instance, the fabric can be placed on a tenter frame and subjected to a hot air blanket, such as air at a temperature of greater than about 200 F., such as greater than about 250 F., such as greater than about 280 F., and generally less than about 400 F., such as less than about 350 F. In one embodiment, the fabric is placed on the tenter frame and the fabric is overfed in order to maintain the fabric in a relaxed condition. While on the tenter frame, one or more chemical finishes can be applied to the fabric. For instance, in one embodiment, a water repellant composition can be applied to the fabric and cured.

[0072] In one embodiment, a chemical composition is applied to both sides of the fabric. The composition can be applied to the fabric by plasma treatment, sprayed on the fabric, dipped into the composition, or printed on to the fabric. In one embodiment, the chemical composition is not coated on the fabric but rather substantially impregnated on the fabric.

[0073] In one embodiment, the composition is applied to the fabric at a wet pick up rate of from about 10% to about 50% by weight of the fabric, particularly from about 20% to about 25% by weight.

[0074] The outdoor cover product or fabric made in accordance with the present disclosure can have a unique combination of properties that makes the fabric well suited for use in outdoor applications. For instance, the fabric can have a spray rating when tested according to AATCC Test 22 of at least 90, such as at least 95, such as even a rating of 100. The outdoor cover product or fabric can display a hydrostatic pressure when tested according to AATCC Test 127 of at least 10 cm, such as at least 11. The hydrostatic pressure is generally less than about 25 cm.

[0075] The outdoor cover product or fabric can also have excellent air permeability properties. For instance, the fabric, when tested according to ASTM Test D737, can have an air permeability of greater than about 50 cfm, such as greater than about 60 cfm, such as greater than about 70 cfm. The air permeability is generally less than about 100 cfm.

[0076] Preferred embodiments of the present disclosure involve the use of the fabric in the construction of materials for outdoor applications. Items that benefit from improved hydrostatic pressure and UV resistance may be constructed from the fabric described herein. For example, automotive and marine applications, awnings, casual outdoor furniture, tents, umbrellas, covers, canopies, banners, military applications, sun shades, protective engine or seat covers, and the like may be constructed using the fabric of the present disclosure. Additionally, many items benefit from the fire resistant capabilities of the fabric of the present disclosure. Such items can include, without limitation, indoor or outdoor awnings, tents, canopies, umbrellas, casual outdoor furniture, and the like.

[0077] With Reference to FIG. 1, an outdoor awning or shade 10 is illustrated. As shown, the shade 10 can be attached to a structure or building. If desired, the shade 10 can be associated with a frame for maintaining a certain shape. In the embodiment illustrated in FIG. 1, the shade 10 is connected on 3 corners to the budding and the ground. On the remaining corner, the shade 10 is attached to a frame 12.

[0078] Referring to FIG. 2, a shade structure for a boat is illustrated. The shade structure 20 is attached to various frame members 22. The frame members 22 can form a frame structure and can be formed from polls or the like. The shade 20 can extend over an open part of the boat for providing shade to the occupants.

[0079] With reference to FIG. 3, an umbrella 30 is illustrated. The umbrella 30 includes a frame 32. The frame 32 can extend outward from a central shaft 36. The frame 32 is covered by fabric or outdoor cover product 34 as described in the present disclosure.

[0080] Finally, with reference to FIG. 4, a piece of outdoor furniture is illustrated, specifically a folding chair 40. The folding chair 40 includes support elements 42. The support elements 42 are covered by fabric or outdoor cover product 44 as described in the present disclosure. It should be understood that the fabric may include padding or cushioning as would be known in the art.

EXAMPLES

[0081] The present disclosure may be better understood with reference to the following examples.

[0082] Three outdoor cover products were made in accordance with the present disclosure. One product contained a fabric having a basis weight of 5.79 osy (Sample No. 1), another fabric had a basis weight of 7.23 osy (Sample No. 2), and the third fabric had a basis weight of 6.49 osy (Sample No. 3). The fabrics were constructed from solution dyed multifilament yarns containing polyester filaments. The yarns contained a UV stabilizer. The fabrics were made from multifilament yarns having a denier of 300. The multifilament yarns were highly texturized and contained from about 100 to about 125 tie downs per meter.

[0083] The yarns were woven into a fabric and subjected to a shrink process by being fed to a jet dye machine and exposed to water at a temperature above 220 F. at a relaxed state. The fabric was then relaxed dried.

[0084] The fabrics were also treated with a water resistant composition. The water resistant composition comprised SHELL TEC 6 finish commercially available from Bolger and O'Hearn, Inc. The treated fabric was overfed and cured on a tenter frame.

[0085] The fabrics were tested for various properties and the following results were obtained:

TABLE-US-00001 Sample Sample Sample Method No. 1 No. 2 No. 3 Weight, oz/sq yd ASTM D 3776 5.79 7.23 6.49 Width, Inches ASTM D 3774 61 61 60 Ends/Inch ASTM D 3775 55 55 55.5 Picks/Inch ASTM D 3775 51 37.5 41 Spray Rating, AATCC 100 100 100 Hydro static, cm AATCC 127 11 11 12 Perm, CFM ASTM D 737 80 58 75 Oil repellency AATCC 118-1983 6 6 6 Water Repellency AATCC- Dupont 6 6 6 Tensile, Pounds, W F ASTM D 5034 234 228 225 290 230 259 % Elongation, W F ASTM D 5034 88 95 88 100 90 95 Tongue T, #'s, W F ASTM D 2261 15.7 15.4 29.8 18.9 20.1 15.7 % Stretch, warp 13 11 12 % Stretch fill 18 19 20

[0086] These and other modifications and variations to the present disclosure may be practiced by those of ordinary skill in the art, without departing from the spirit and scope of the present disclosure, which is more particularly set forth in the appended claims. In addition, it should be understood that aspects of the various embodiments may be interchanged both in whole or in part. Furthermore, those of ordinary skill in the art will appreciate that the foregoing description is by way of example only and is not intended to limit the disclosure so further described in such appended claims.