Outdoor Cover Product with Stretch Properties

Abstract

An outdoor cover product is disclosed. The outdoor cover product is water resistant and breathable. The product is made from a fabric, such as a knitted 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 fabric having wales and courses comprised of multifilament yarns containing polyester filaments, polyamide filaments, polypropylene filaments, polyethylene filaments, polytetrafluoroethylene filaments, or mixtures thereof, the fabric having an interlock knit weave such that the fabric has an elasticity of greater than or equal to 25% in the longitudinal direction and in a lateral direction at a force of 25 lbs.

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

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

4. 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.

5. An outdoor cover product as defined in claim 1, wherein the fabric has an elasticity of greater than or equal to 50% in the longitudinal direction and in the lateral direction at a force of 50 lbs.

6. An outdoor cover product as defined in claim 1, wherein the multifilament yarns contained in the fabric contain polyamide filaments.

7. An outdoor cover product as defined in claim 1, wherein the multifilament yarns contained in the fabric contain polyester filaments.

8. An outdoor cover product as defined in claim 1, wherein the fabric has a basis weight of from about 4.5 osy to about 8 osy.

9. An outdoor cover product as defined in claim 1, wherein the fabric has a basis weight of from about 10 osy to about 15 osy.

10. An outdoor cover product as defined in claim 1, wherein the fabric contains from about 32 to about 38 courses per inch.

11. An outdoor cover product as defined in claim 1, wherein the fabric contains from about 27 to about 40 wales per inch.

12. An outdoor cover product as defined in claim 1, wherein the fabric has a spray rating of 100.

13. 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.

14. An outdoor cover product as defined in claim 1, wherein the cover has an air permeability of at least 65 cfm when tested according to ASTM Test D737.

15. An outdoor cover product as defined in claim 1, wherein the fabric comprises a circular knit fabric.

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.

20. An outdoor cover product as defined in claim 2, wherein the multifilament yarns contain polyamide filaments, polyester filaments, or mixtures thereof, the fabric being non-coated and not laminated to any other film or fabric layer, the fabric containing from about 32 to about 38 courses per inch, the outer cover product having a hydrostatic pressure of from about 11 cm to about 15 cm when tested according to Test AATCC 127, the outer cover product having an air permeability of at least 70 cfm when tested according to ASTM Test D737.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0035] 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:

[0036] FIG. 1 represents a shade structure in accordance with one embodiment of the present disclosure;

[0037] FIG. 2 represents another embodiment of a shade structure in accordance with the present disclosure;

[0038] FIG. 3 represents an umbrella in accordance with one embodiment of the present disclosure;

[0039] FIG. 4 represents a piece of outdoor furniture in accordance with one embodiment of the present disclosure;

[0040] FIG. 5 is a perspective view of one embodiment of an interlock knit weave that may be used to produce the fabric of the present disclosure; and

[0041] FIG. 6 is a plan view of one embodiment of a knitted fabric made in accordance with 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. The fabric can also be elastic such that the fabric recovers after being stretched.

[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 yarns. 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. In addition, a chemical composition is applied to the fabric which can improve the resistance of the fabric to the penetration of water under hydrostatic pressure without the mark off typical of both coated and non-coated fabrics. 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 of 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 exempla 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 or knitted into various constructions. A particular weave or knit may be selected to provide durability, breathability, and ease of fabrication. In accordance with the present disclosure, the yarns are woven or knitted into a fabric that has multidirectional stretch properties. In one embodiment, the stretch properties may also be elastic in that the fabric will experience a recovery once stretched. The knitted or woven fabric Can have any suitable structure, such as a double knit, a double jersey, an interlock knit fabric, a double raschel, a double knitted fabric, a double cloth, a single jersey, or a smooth knitted fabric.

[0050] In one embodiment, the fabric of the present disclosure comprises a knitted fabric having an interlock knit, such as a circular knit. One embodiment of a fabric made in accordance with the present disclosure is illustrated in FIGS. 5 and 6. FIG. 6 is an illustration of the woven fabric, while FIG. 5 is an enlarged view of the knit structure. As shown in FIG. 5, a knit fabric 14 is constructed from wales 15 and courses 17. Wales 15 comprise a vertical column of intermeshed loops. The number of wales determines the width of the fabric. The courses 17, on the other hand, are rows of loops across the width of the fabric produced by adjacent needles during the same knitting cycle that produces the wales. The courses determine the length of the fabric.

[0051] The fabric illustrated in FIGS. 5 and 6 has an interlock knit structure. Interlock knit fabrics generally have the appearance of a plain fabric on both sides. Interlock knit fabrics are constructed from two rows of stitches, one directly behind the other. In this manner, the surface cannot be stretched out to reveal the reverse meshed loop wales because the wales on each side are exactly opposite to each other and are locked together. Interlock knit fabrics can create the impression that the fabric is comprised of two layers but, as described above, the wales are locked together. An interlock pattern row requires two feeder courses, each with a separate yarn that knits on separate alternate needles to produce two rib courses whose sinkers loops cross over each other to produce the structure as shown in FIG. 5.

[0052] Interlock knit fabrics are generally smooth on both sides of the fabric. Of particular advantage, fabrics made according to the present disclosure using the interlock knit structure not only have smooth surfaces but also have excellent stretch properties while remaining stable. Of particular advantage, interlock knit fabrics can be made in accordance with the present disclosure with excellent recovery properties. In particular, once stretched, the fabric can bounce back to its original size without any permanent distortion.

[0053] In one embodiment, the fabric of the present disclosure is capable of stretching from about 30% to about 100% of its original size in at least two directions. As used herein, the stretch properties of a fabric are determined according to ASTM Standard Test Method D2594, which is typically used to measure the stretch properties of knitted fabrics having low power. The fabric can also have recovery such that when tension is released it goes back to at least 90%, such as at least 95%, such as back to 100% of its original size. In one particular embodiment, for instance, the fabric of the present disclosure can have stretch properties such that the fabric elongates at least 25%, such as at least 30% in both the length or vertical direction and the width or transverse direction when placed under 25 lbs. of force. The fabric can also stretch at least about 30%, such as at least about 35% in both the length or vertical direction and the width or transverse direction when subjected to 50 lbs. of force. In general, the fabric stretches no more than about 100%, such as no more than about 70%, when subjected to the above amount of forces. As described above, in one embodiment, the fabric can also have excellent elastic properties. In this regard, the fabric can recover at least 90%, such as at least 95%, such as even 100% when stretched in the length or vertical direction and when stretched in the width or transverse direction at either 25 lbs. of force or at 50 lbs. of force.

[0054] 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 8 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 10 osy to about 15 osy, such as from about 12 osy to about 13 osy.

[0055] 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 multifilament yarns and does not contain any spun yarns. 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 150 to about 900. It may also be desirable to texturize multifilament yarns with air jet texturing or plying. In one embodiment, the denier of the multifilament yarns may be about 800 or less, such as about 400 or less, such as about 300 or less. In one embodiment, the multifilament yarns can have a denier of from about 200 denier to about 400 denier, such as at a denier of about 300 for fabrics having a heavier basis weight. 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, such as at a denier of about 150.

[0056] 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. When forming a knit fabric, such as an interlock knit fabric, the density of the courses can be greater than about 30 courses per inch, such as greater than about 32 courses per inch, such as greater than about 34 courses per inch. The courses per inch is generally less than about 40, such as less than about 38, such as less than about 36 courses per inch. The number of wales per inch in the fabric can be generally greater than about 20 wales per inch, such as greater than about 23 wales per inch, such as greater than about 25 wales per inch, such as greater than about 27 wales per inch, such as greater than about 30 wales per inch, such as greater than about 33 wales per inch. The fabric can contain wales in an amount generally less than about 50 wales per inch, such as in an amount less than about 55 wales per inch, such as in an amount less than about 40 wales per inch, such as in an amount less than about 38 wales per inch, such as in an amount less than about 35 wales per inch.

[0057] 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.

[0058] 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 & O'Hearn Inc. Fluorocarbon polymer solutions are also commercially available from other numerous sources and suitable for use herein.

[0059] Besides containing a fluorocarbon polymer, the chemical composition can also contain various other additives.

[0060] 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.

[0061] 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 benefically 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.

[0062] 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 non conductive and can be utilized where flammability is a concern.

[0063] 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 fluorocarbon polymer can have a tendency to burn, the weight percentages of fluorocarbon polymer and fire resistant agent as described herein is important in maintaining the fire resistance of the fabric.

[0064] 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.

[0065] 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.

[0066] In order to produce a liquid resistant fabric in accordance with the present disclosure, after the fabric is constructed, the fabric can first be scoured, although scouring may not be necessary for all applications. After scouring, the fabric will be dried.

[0067] After these processing steps, a chemical composition according the present disclosure is supplied to both sides of the fabric. Although the treatment can be applied by plasma treatment, sprayed on the fabric, or printed on the fabric, preferably the fabric is dipped into a bath containing the chemical composition in solution form wherein the chemical composition is not coated on the fabric but rather substantially impregnated on the fabric.

[0068] 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.

[0069] After the chemical composition is applied to the fabric, the fabric is then heated to a temperature sufficient for the finish to dry and/or cure. In one particular embodiment, the finish may be cured by heating the fabric to a temperature of about 360 F. for approximately 20-25 seconds. In some embodiments, after curing the finish, the fabric is passed through a calender under at least 1000 psi to help reduce the mark off of the fabric. Once the chemical composition is cured and affixed to the fabric, the fabric can then be used in constructing materials for outdoor applications.

[0070] 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 cm, such as at least 12 cm. The hydrostatic pressure is generally less than about 25 cm.

[0071] 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 60 cfm, such as greater than about 65 cfm, such as greater than about 70 cfm. The air permeability is generally less than about 100 cfm. After being laundered, the fabric can be made so as to experience relatively no shrinkage. For instance, after being laundered and tested according to AATCC Test 96, the fabric may display length-wise shrinkage and/or width-wise shrinkage of less than about 1%, such as less than about 0.5%.

[0072] 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.

[0073] 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 building and the ground. On the remaining corner, the shade 10 is attached to a frame 12.

[0074] 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.

[0075] 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.

[0076] 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

[0077] The present disclosure may be better understood with reference to the following examples.

[0078] Two outdoor cover products were made in accordance with the present disclosure. One product contained a fabric having a basis weight of 12.2 osy (Sample No. 1), while the other fabric had a basis weight of 6.9 osy (Sample No. 2). The fabrics were constructed from solution dyed multifilament yarns containing polyester filaments. The yarns contained a UV stabilizer. The higher basis weight fabric is made from multifilament yarns having a denier of 300, while the lower basis weight fabric was made from yarns having a denier of 150.

[0079] The yarns were woven into knit fabrics having an interlock knit structure. 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.

[0080] The fabrics were tested for various properties and the following results were obtained:

TABLE-US-00001 Sample Sample Method Units No. 1 No. 2 Weight, oz/sq 2 ASTM D 3776 osy 12.2 6.9 Courses/Inch ASTM D 3775 Threads/Inch 33 34 Wales/Inch ASTM D 3775 Threads/Inch 29 37 Thickness ASTM D 1777 Inch 0.038 0.033 pH AATCC 81 pH 7.8 Spray Rating AATCC 22 AATCC 100 100 Scale Hydrostatic AATCC 127 cm 13 13 Pressure Air Permeability ASTM D 737 cfm 73.5 73.5 Oil repellency AATCC 118 AATCC Scale 6 6 Water Repellency AATCC 193 AATCC Scale 6 6 Laundering AATCC 96 Percent 0.30% Shrinkage Length Laundering AATCC 96 Percent 0.20% Shrinkage Width Ball Burst ASTM D 3786 Pounds 242 Table Stretch ASTM D 2594 Percent 10% 20% Length Table Stretch ASTM D 2594 Percent 30% 20% Width Recovery Length ASTM D 2594 Percent 100% 100% Recovery Width ASTM D 2594 Percent 100% 100% Wall Stretch MIL-C-40004C Percent 33% Length Wall Stretch MIL-C-40004C Percent 135% Length Recovery Length MIL-C-40004C Percent 100% Recovery Width MIL-C-40004C Percent 94%

[0081] 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.