Woven fabrics particularly useful in the manufacture of occupant support structures

Abstract

A fabric particularly useful in the manufacture of occupant support structures is described. The fabric is desirably leno woven to have a high degree of openness and such that at least a plurality of the yarn intersections are stabilized from relative motion. The fabric includes elastomeric synthetic yarns in at least one fabric direction. At least some of the points of yarn intersection can be supplementally stabilized from relative motion, such as through the use of bicomponent yarns having a sheath which is melted to secure intersecting yarns together. The fabric is also resistant to ultraviolet irradiation so that it retains its physical properties after accelerated exposure to UV irradiation. The fabric provides good support and ventilation, and is suitable for use as a surface fabric in automotive and seating applications.

Description

FIELD OF THE INVENTION

[0001] The invention generally relates to woven fabric constructions. More specifically, the invention relates to woven fabrics having good durability, strength, dimensional stability and ventilation properties which are particularly adapted for use in the production of occupant support structures such as seating, bedding and the like.

BACKGROUND OF THE INVENTION

[0002] Traditional occupant support structures such as seating, bedding, and the like are generally constructed from a fabric support secured to some form of frame. Often occupant support structures include additional support elements such as springs, cushions, pads, straps, webs or the like. Such additional support elements typically constitute a large part of the overall weight and dimension of the occupant support structures.

[0003] In many end uses it is desirable to minimize the weight of the overall structure. For example, in the manufacture of transport vehicles such as cars and airplanes, the weight of the overall structure can influence variables such as fuel efficiency, freight charges, and the like. Likewise, many occupant support structures for home and office use (e.g. chairs, sofas and the like) are often moved about frequently. In such situations, it would be preferable to minimize the weight of the structure to facilitate its movement. Therefore, it can be desirable in many cases to minimize the weight of the occupant support structures. However, it is also important that they retain the ability to provide proper support and comfort of their particular end use.

[0004] Another disadvantage associated with many conventional forms of occupant support structures is that a number of the materials typically used to produce these structures tend to feel cold or hot to a user depending on the particular environmental conditions. For example, the tendency for an automobile seat to feel hot can be readily appreciated by anyone who has sat on a leather car seat in the summer heat. In addition, the materials are generally not breathable, and therefore they tend to block the flow of air past adjacent portions of a user's body. As a result, the back of the legs of a seated individual can become sweaty and uncomfortable following long periods of sitting on a seat formed of conventional material.

[0005] Furthermore, the difficulty and costs associated with assembly of occupant support structures generally are related to the number of structural elements required for their production. To reduce the complexity of the assembly process, it may therefore in many cases be desirable to manufacture occupant support structures using a minimal number of elements. However, the reduction in the number of elements must be balanced against the need to achieve particular performance capabilities.

[0006] In many end uses, the materials used to produce the occupant support structures are exposed to a variety of degradory forces. For example, seats in automobiles are exposed to a wide range of temperatures, compressive forces, lateral shearing forces and the like. In addition, such support structures are commonly exposed to ultra-violet (UV) irradiation on an extended basis from the sunlight which passes through the windshield and the windows. The UV irradiation tends to undesirably degrade many kinds of materials, rendering them unsuitable for use as surface fabrics in environments where they can be exposed to a high degree of UV irradiation. Therefore, with the minimization of elements, the strength and durability of the elements that are utilized becomes increasingly important. Furthermore, manufacturers must typically take other properties such as tactile properties, hand, drape and the like into consideration to ensure a proper balance of properties is achieved for the particular end use for which the fabric is being manufactured.

[0007] Materials which have been proposed for use in the manufacture of occupant support structures are described in commonly-assigned U.S. Pat. Nos. 5,533,789 and 5,596,888, each to McLarty, III et al., the disclosures of which are incorporated herein by reference. The McLarty '789 patent describes a seating structure having portions made from a weft inserted warp knit fabric. The fabric has an elastomeric monofilament yarn in the warp forming a performance side, an elastomeric wrapped filament yarn in the weft forming an aesthetic surface, and a knit filament yarn tying the warp and the weft together.

[0008] The McLarty '888 patent describes a knit furniture support fabric having multi-directional stretch characteristics and possessing sufficient strength and durability to function as a support in a seating or bed structure. The furniture support fabric is a four bar knit structure including two yarns of textured polyester and two yarns of elastomeric monofilament knit together such that the fabric has an elongation at break of at least 17 percent in both the warp and fill directions. While providing good physical properties for many end use applications, it has been found that fabrics made according to the McLarty '789 and '888 patents have a harsher hand than is desired for some particular end use applications.

[0009] U.S. Pat. No. 4,469,739 to Gretzinger et al. describes woven furniture support materials made in part from elastomer monofilaments and in part from a non-elastomeric yarn. The non-elastomeric yarn is described as being provided in the warp direction of the fabric in the preferred embodiment of the structure. The patent describes that the yarns can be melted at their intersections with each other, or alternatively can be affixed to each other at the intersections by selecting the weaving pattern to be of such a configuration that the yarn will lock in place about the filament, thereby obviating the need for adhesive or melting of the elastomer.

[0010] As noted above, many fabrics used as components in occupant support structures are exposed to ultraviolet irradiation for extended periods of time. For example, automotive seating materials, outdoor chairs and the like experience extended exposure to UV irradiation. In many cases, the UV irradiation exposure degrades the fibers forming the fabrics, thereby undesirably limiting the useful life of the structure or rendering certain fabrics unsuitable for particular end uses.

[0011] An example of a fabric capable of resisting degradation due to exposure to UV irradiation is described in commonly-assigned U.S. Pat. No. 5,856,249 to Waldrop et al., the disclosure of which is incorporated herein by reference. The Waldrop patent describes a fabric having a plurality of elastomeric synthetic yarns running in a first direction interwoven with a plurality of synthetic yarns running in a second direction substantially transverse to the first direction, where the elastomeric synthetic yarns running in the first direction comprise not less than about 40 percent by weight of the textile fabric. The elastomeric yarns running in the first direction are further characterized by the fact they have an elongation at break of not less than about 50 percent, and they retain not less than about 80 percent of their tensile strength upon accelerated exposure to 488 kilojoules of ultraviolet irradiation. The patent describes that the fabric is preferably a woven fabric, and particularly, one which is woven in a barathea weave construction. Because of its resistance to degradation from exposure to UV irradiation, the fabric can be used as a surface material in automotive seating applications.

[0012] In addition, commonly-assigned co-pending patent application Ser. No. 09/224,980 to Waldrop et al., filed Jan. 4, 1999, describes a fabric useful as an automotive upholstery surface fabric. The disclosure of the '980 application is incorporated herein by reference. The fabric has a plurality of elastomeric synthetic yarns running in a first direction and a plurality of synthetic yarns running in a second direction substantially transverse to the first direction, with the elastomeric synthetic yarns running in the first direction comprising not less than about 40 percent by weight of the upholstery fabric. The elastomeric synthetic yarns running in the first direction have an elongation at break of not less than about 70 percent and are UV stabilized.

SUMMARY

[0013] The instant invention overcomes disadvantages associated with conventional structures through the provision of a fabric having desirable levels of durability, strength, dimensional stability, and elastomeric properties, rendering it particularly well-suited for use in the manufacture of occupant support structures. The fabric of the invention has a good hand and retains desirable physical properties, even after extended periods of exposure to ultraviolet irradiation. As a result, it performs well as a surface fabric in occupant support structures such as automobile seats and the like. Furthermore, the fabric of the instant invention has a large degree of openness, so as to provide good ventilation characteristics. Because of its unique construction, the fabric can be secured to a frame alone (i.e., without other fabric layers) to form a support structure or it can be used in combination with other layers as desired. Furthermore, the fabric can be cut into pieces of desired shape and size, and fabricated into an end use product without undesirable levels of fabric degradation through raveling or the like.

[0014] The fabrics of the invention achieve the desired properties by utilizing elastomeric synthetic yarns in an open weave structure formed by first and second sets of intersecting yarns. The fabric is preferably woven in a leno weave or a variation thereof so that warp yarns of the fabric are locked around at least some of the fill, yarns. Yarns of the first and second yarn sets are also desirably supplementally secured together at their intersections.

[0015] In a preferred form of the invention, the elastomeric synthetic yarns are preferably provided in the warp, and desirably are of the bicomponent sheath/core variety. The sheath component desirably has a melting temperature which is below that of the core component, so that the sheath can be melted subsequent to weaving to lock the yarns of the respective yarn sets together at their intersections. The other yarn set may or may not include elastomeric synthetic yarns, with the yarn used desirably being selected to provide the fabric with a particular combination of physical characteristics, such as a good hand and aesthetic appearance.

[0016] At least some of the yarns forming the fabric are desirably UV-resistant so that the fabric retains at least about 50%, and more preferably at least about 70% of its initial breaking strength when measured in the elastomeric synthetic yarn direction and at least about 50% of its initial breaking strength when measured perpendicular to the elastomeric synthetic yarn direction following accelerated exposure to 225 kilojoules of UV irradiation.

[0017] The fabric has high strength and dimensional stability, and resists unraveling. In addition, the fabric is also desirably open, so that at least about 15% of a given area of the fabric is open area, and more preferably at least about 30%. Even more preferred is that the fabric constitutes at least about 35%, and more preferably at least about 40% open area. In fact, it has been found that fabrics having at least about 45% open area can be made according to the instant invention, while retaining sufficient strength and dimensional stability to enable them to be used in the formation of occupant support structures. In addition, products made according to the invention using yarns which are resistant to UV irradiation are particularly useful in the formation of occupant support structures which are exposed to UV irradiation on an extended basis, such as automotive seating.

DETAILED DESCRIPTION

[0018] In the following detailed description of the invention, specific preferred embodiments of the invention are described to enable a full and complete understanding of the invention. It will be recognized that it is not intended to limit the invention to the particular preferred embodiments described, and although specific terms are employed in describing the invention, such terms are used in a descriptive sense for the purpose of illustration and not for the purpose of limitation.

[0019] The fabric of the instant invention is constructed to provide a high degree of fabric openness. Preferably, at least about 15% of the surface area of a piece of fabric constitutes open space (i.e. space between the fibers or yarns forming the fabric), and more preferably at least about 30%. Even more preferably, at least about 35% of the fabric is open space, and more preferably about 40%. In some embodiments of the invention, it will be desired to have at least about 45% of the area of the fabric constitute open area.

[0020] The fabric according to the invention desirably includes a first set of yarns extending in a first direction and a second set of yarns extending in a second direction which is generally transverse to the first direction. For example, the fabric is desirably a woven fabric in which one of the first and second yarn sets is a warp yarn set and the other of the first and second yarn sets is a weft (i.e. filling) yarn set.

[0021] The fabric is woven to include a plurality of elastomeric synthetic yarns in at least one of the first and second yarn sets, preferably in the warp yarn set. In some embodiments of the invention, elastomeric synthetic yarns are included in both the first and second yarn sets. In a preferred form of the invention, the elastomeric synthetic yarns are preferably monofilament yarns having an elongation at break of at least about 50%, and preferably a tensile strength of at least about 8 pounds force prior to weaving, and more preferably at least about 8.5 pounds force. Even more preferably, the elastomeric synthetic yarns are monofilament yarns having an elongation at break of at least about 75%, and more preferably at least about 90%, and even more preferably at least about 100%.

[0022] In a particularly preferred form of the invention, the elastomeric synthetic yarns are of the sheath/core variety in which the sheath has a lower melting temperature than that of the core component. In this form of the invention, the melting temperature of the sheath is desirably at least about 30° F. lower than that of the core, for reasons which will be discussed more fully hereinafter. Elastomeric synthetic yarns which have been found to perform particularly well in the invention are distributed under the tradename ELAS-TER® by Johns Manville of Spartanburg, S.C. (formerly Hoechst Celanese.)

[0023] The yarns forming the second yarn set can be any of a variety of materials, depending on the intended end use of the fabric For example, in one form of the invention the second yarn set also includes elastomeric synthetic yarns, either alone or in combination with one or more other types of yarns. For example, the fill can include other types of elastomeric yarns, polyester, nylon, natural Taslan polyester, elastomeric/Taslan polyester yarn combinations, polyester wrapped ELAS-TER® yarns, combinations thereof, or any other type of yarn or yarn combination which achieves the desired end properties. In most forms of the invention, it will generally be preferred to include other types of yarns in the second yarn set (either alone or in combination with an elastomeric synthetic yarn component) in order to provide particular functional and aesthetic properties to the fabric. For example, in many cases it will be desirable to use a yarn in the second yarn set which provides the fabric with a soft hand or the like (e.g. through the use of a textured or spun yarn and in particular, one having an overall cross-sectional diameter which is greater than that of the elastomeric synthetic yarn, so that it extends outwardly from the fabric to form an aesthetically pleasing fabric surface.) Alternatively, the second yarn set can be devoid of elastomeric synthetic yarns, depending on the particular end use intended for the fabric and physical characteristics desired. In addition, a single yarn can be inserted in each shed during the weaving process or a plurality of yarns can be inserted in one or more of the sheds. Furthermore, it is noted that the elastomeric yarns can be provided in the fill while other types of yarns are used to form the warp. However, it is preferred to provide the elastomeric synthetic yarns in at least the warp direction.

[0024] In a preferred form of the invention particularly useful in the manufacture of automotive upholstery, the second yarn set includes a Taslan polyester yarn about 600-2200 denier in size. This yarn can be used alone to form the second yarn set, or it can be used in combination with an elastomeric synthetic yarn similar to or the same as that used in the first yarn set. In such a combination, the elastomeric synthetic yarn component and the other yarn component can be combined prior to weaving (e.g. through a texturing or twisting process or the like), or the two components can be inserted together during the weaving process, without first being combined together. Again, the particular arrangement of the filling yarns will be selected to achieve the physical and aesthetic properties desired.

[0025] The fabric is desirably woven in a construction wherein at least some of the warp and fill yarns are locked together by virtue of the weave construction rather than simply intersecting in the manner of a plain weave construction. Preferably, the weave construction used to stabilize the points of intersection is a leno weave construction or a variation of a leno weave construction. (As will be appreciated by those having ordinary skill in the art, a leno weave includes pairs of warp yarns which cross as they encircle and secure the filling yarns. As used herein, the term “leno” is intended in its broadest meaning and to include all variations of leno weave.) In a preferred form of the invention, all of the warp yarns are woven in a leno fashion; however, fabrics having only a portion of the warp yarns woven in a leno fashion are also within the scope of the instant invention. For example, a pattern of alternating leno and plain woven warp yarns can be utilized. Alternatively, other weave constructions that secure at least some of the yarn intersections from relative motion can be used within the scope of the invention.

[0026] Preferably, at least some of the points of intersection are also supplementally secured from relative motion with respect to each other. For example, in a preferred form of the invention, at least a portion of the yarns used to construct the woven fabric are thermoplastic, so that they can be melted during a heat setting operation to secure the points of intersection of yarns in the respective first and second yarn sets from relative motion. In a particularly preferred form of the invention, at least some of the points of intersection are secured by both the particular weave construction utilized and by a supplemental securement.

[0027] In one aspect of the invention, at least some of the yarns used to form the fabric are sheath/core bicomponent yarns, having a sheath component with a lower melting temperature than the core component. In this way, the fabric can be subjected to a temperature greater than that of the melting point of the sheath (but preferably below the melting point of the core component) to melt the sheath, and when the sheath is re-solidified, it can serve to bond the woven fabric together at the point of yarn intersection. To this end, it is preferable to utilize as the elastomeric synthetic yarn a sheath/core yarn having a sheath which has a melting temperature which is at least about 30° F. lower than that of the core. Because of their unique construction, the fabrics of the invention can be readily and efficiently cut and sewn without the raveling generally associated with prior art fabrics.

[0028] The fabric is also designed to be resistant to UV irradiation, in order that it retains its strength and other physical characteristics even after extended exposure to UV irradiation. In particular at least some of the yarns, and preferably substantially all of the yarns, forming the fabric are resistant to UV irradiation. In particular, the yarns desirably retain a substantial portion of their original tensile strength and elongation characteristics following exposure to high levels of UV irradiation for extended periods of time. In a preferred form of the invention, at least one of the first and second yarn sets contains elastomeric synthetic yarns which are UV resistant. In a particularly preferred form of the invention, UV-resistant elastomeric synthetic yarns-are utilized to form the warp yarns of the fabric. The UV-resistant elastomeric synthetic yarns desirably retain at least about 80%, and more preferably at least about 90%, of their original tensile strength upon accelerated exposure to 488 kilojoules of UV irradiation in compliance with SAE testing standard J 1885. In a particularly preferred form of the invention, the UV-resistant elastomeric synthetic yarns retain at least about 95% of their tensile strength upon accelerated exposure to UV irradiation. For example, a sample of an elastomeric synthetic yarn useful in performing the instant invention was tested prior to weaving, where it exhibited a tensile strength of approximately 8.9 pounds force and an elongation at break of about 124%, and after accelerated exposure to UV irradiation at a level of 488 kilojoules in compliance with SAE testing standard J1885 exhibited a tensile strength of 7.1 pounds force and an elongation at break of approximately 115%.

[0029] As mentioned, fabrics of the instant invention are desirably woven in a leno weave with the elastomeric synthetic yarns forming at least about 40% by weight of the total fabric, and are woven to produce a relatively open structure. For example, in a preferred embodiment of the invention, a fabric is leno woven using a 2250 denier elastomeric monofilament polyester disposed in the fabric at a weave density of about 20 ends per inch. The filling is desirably a polyester yarn which is 300 denier or greater in size, and which may or may not include an elastomeric synthetic yarn component. For example a 1650 denier Taslan yarn has been found to perform well in the instant invention. In addition, the use of a 1650 denier Taslan polyester in combination with a 400 denier elastomeric synthetic yarn has been found to achieve a fabric having good physical characteristics. The fill density is desirably from about 4 picks per inch to about 30 picks per inch. As noted, a plurality of fill yarns of one or more types may be provided in a single shed.

[0030] The fabrics, which desirably utilize sheath/core bicomponent yarns as the elastomeric synthetic yarns, are preferably heat treated to melt the sheath component and secure the first and second yarns sets at their respective yarn intersections. The yarns are then allowed to cool so that the melted material re-solidifies to form a good bond between the yarns of the respective yarn sets.

[0031] Fabrics made according to the instant invention desirably retain at least about 50%, and more preferably at least about 70% of their original breaking strength when measured in the elastomeric synthetic yarn direction and at least about 50% of their original breaking strength when measured in the other generally transverse direction following exposure to a cumulative irradiation of 225 kilojoules in accordance with SAE Standard J 1885. Preferably, the fabric has an elongation at break in the elastomeric synthetic yarn direction of at least about 70% before and after exposure to accelerated levels of UV-irradiation of 225 kilojoules and they retain at least about 50%, and more preferably at least about 70% of their tensile strength in the elastomeric synthetic yarn direction following accelerated UV irradiation exposure. Furthermore, the fabrics have unique combinations of strength, durability, and dimensional stability as well as desirable aesthetic properties such as hand. Additionally, the fabrics made according to the invention can be cut and sewn without raveling, rendering them easier to use in the production of occupant support structures than prior art fabrics, and minimizing fabric waste due to raveling.

EXAMPLES

[0032] Fabrics were prepared as follows and tested for purposes of comparison according to the tests described below. Each of the fabrics was produced on a standard rapier weaving machine utilizing a reed width of 69 inches and a beam width of 69 inches. The fabrics were woven in the respective manner described, and heat setting was performed at about 3900 F to bond the intersections of the yarn sets.

[0033] Sample A was fabricated in a conventional manner, to resemble a commercially-available product. The fabric was woven in a leno construction to include oval-shaped elastomeric yarns in the warp and elastomer/Taslan polyester yarns in the fill. None of the yarns used were UV stabilized, and the fabric was not heat set in the manner of the instant invention.

[0034] Sample B was manufactured according to the instant invention. The fabric was formed in a leno weave construction with the warp being formed from 1000 denier UV-stabilized ELAS-TER® yarns, while the fill included elastomer/Taslan polyester yarns. The fabric was heat set to melt the sheath of the ELAS-TER® yarns and secure the points of intersection between the warp and fill yarn sets.

[0035] Sample C was manufactured according to the instant invention. The fabric was formed in a leno weave construction using 2250 denier UV-stabilized ELAS-TER® yarns in the warp and with two elastomer/Taslan polyester combination yarns and two natural Taslan polyester yarns being inserted in alternating fashion in each shed. In other words, each shed included a filling yarn combination of one elastomer/Taslan yarn, one natural Taslan yarn, a second elastomer/Taslan yarn, and a second natural Taslan yarn. The fabric was heat set according to the instant invention to melt the ELAS-TER® yarns, to thereby supplementally secure the points of intersection between the warp and fill yarn sets.

[0036] Sample D was manufactured according to the instant invention. The fabric was formed in a leno weave construction using 2250 denier UV-stabilized ELAS-TER® yarns in the warp and 400 denier ELAS-TER® wrapped with 70 denier polyester yarn in the fill. The fabric was heat set according to the instant invention to melt the ELAS-TER® yarns, to thereby supplementally secure the points of intersection between the warp and fill yarn sets.

[0037] Sample E was manufactured according to the instant invention. The fabric was formed in a leno weave construction using 1000 denier UV-stabilized ELAS-TER®) yarns in the warp and a 400 denier ELAS-TER®) wrapped with 70 denier polyester yarn in the fill. The fabric, was heat set according to the instant invention to melt the ELAS-TER® yarns and supplementally secure the points of intersection between the warp and fill yarn sets.

[0038] The fabric was tested using a Yarn Unravel Test as described below. The procedure closely followed the Trap Tear Test described in ASTM D1117-14 and was conducted as follows: Fabric samples were obtained by cutting 3 inch×3 inch swatches of each of the fabrics to be tested. A Sintech Tensile tester was used having top and bottom jaws which were 2 inches×3 inches. A gauge length of about 3/inch was used to obtain about 2 inches of yarn unraveling. The cross head speed was set at 12 inches per minute. The sample was clamped in the bottom jaws of the tensile tester first. One yarn was pulled loose one inch and clamped in the upper jaw of the tensile tester. The machine was started and the five high readings (as per normal procedures used in the trap tear procedure referenced above, so that extreme values were eliminated by the program) were averaged. The fabrics were tested in both the warp and fill directions, and the mean values of the pounds strength required to pull the yarns from the fabric were calculated. The results of the Yarn Unravel Test are listed in the table below. 1 UNRAVEL TEST SAMPLE WARP MEAN (lbs.) FILL MEAN (lbs.) A 0 0.189 B 8.993 3.811 C 19.418 4.589 D 2.139 1.374 E 0.679 0.634

[0039] As noted above, the fabric manufactured according to conventional method (i.e. Sample A) offered essentially no resistance to unraveling in the warp direction, and only slight resistance in the fill direction, i.e. 0.189 pounds strength. In contrast, the fabrics made according to the instant invention (i.e. Samples B-E) provided significantly greater resistance to yarn unraveling, as evidenced by the significantly higher forces required to unravel yarns in each of the warp and fill directions. Preferably, fabric made according to the instant invention exhibited a mean value of at least about 0.5 pounds strength resistance to unraveling in each of the warp and fill directions. Even more preferably, the fabrics had a resistance of at least about 2 pounds strength in the warp direction and at least about 1 pound in the fill direction. Even more preferably, the fabric had a resistance of at least about 8 pounds in the warp direction and at least about 3 pounds in the fill direction. Even more preferable is a fabric having at least about 15 pounds in the warp direction and at least about 4 pounds in the fill direction.

[0040] Samples A-E were each also subjected to a Wire Test (as follows) in both the warp and fill direction, and the mean strength was calculated in each direction. A hooked wire (similar to a fish hook) was hooked through the fabric to capture approximately 3-4 ends or picks of the fabric (depending on the type of fabric being tested and the fabric direction being tested.) The force required to cause the hooked yarns to pull from the fabric was measured and recorded. The test was performed five times in each direction, and the mean values calculated. The results are listed below: 2 WIRE TEST SAMPLE WARP MEAN (lbs.) FILL MEAN (lbs.) A 0.9 3.014 B 81.381 13.451 C 94.248 27.464 D 15.093 10.145 E 4.994 11.247

[0041] As evidenced in the table above, the fabrics made according to the instant invention exhibited much greater strength than that of the conventional construction (Sample A). Preferably, fabrics made according to the instant invention have a resistance of at least about 4 pounds in the warp and at least about 10 pounds in the fill, more preferably has a warp resistance of at least about 15 pounds, more preferably at least about 80 pounds, and more preferably at least about 90 pounds. Similarly, resistance in the filling is desirably at least about 10 pounds, more preferably at least about 13 pounds, and even more preferably at least about 25 pounds.

[0042] Samples A-E were further subjected to a Skewer/Tear Test as follows: a piece of the fabric being tested was inserted within a slot formed in the side edge of a small metal plate. The slot was approximately ½ inch (˜1.1 cm) in depth, such that about a ½ inch (˜1.1 cm) section of the edge of the fabric was contained within the slot. The metal plate included first and second openings approximately {fraction (3/32)} inch (˜0.025 cm) in diameter which were spaced apart about ¼ inch (˜0.065 cm) from each other and spaced inwardly from the edge of the plate about {fraction (7/16)} inch (˜0.5 cm), so that the openings overlay the slot formed in the side of the plate. A handle having first and second prongs extending outwardly therefrom was provided, with the prongs being spaced apart the same distance as the openings in the metal plate. After insertion of the fabric edge into the slot, the prongs were then inserted through the openings (which extend through the entire dimension of the plate) such that the fabric was effectively skewered in position within the slot at a position about {fraction (7/16)} inch (˜0.5 cm) inwardly from its edge. The metal plate (holding the first end of the fabric) and free end of the fabric were then pulled apart by a machine designed to measure the amount of force required to pull the {fraction (7/16)} inch (˜0.5 cm) edge of the fabric loose from the rest of the fabric structure. The test was performed five times for each of the warp and fill directions, and the warp and fill means calculated. The results of this test are listed below: 3 SKEWER/TEAR TEST SAMPLE WARP MEAN (lbs.) FILL MEAN (lbs.) A 4.532 12.101 B 99.271 66.873 C 44.672 52.995 D 39.993 20.188 E 27.914 28.972

[0043] As illustrated, the fabrics of the instant invention have superior strength and dimensional stability as compared with those of the prior art. In fact, it has been found that the superior dimensional stability and ravel resistance enables the fabrics of the instant invention to be cut and manipulated in the fabrication of the end use products, a feature that was heretofore impossible with the comparable prior art fabrics.

[0044] Samples B, C and D (as described above) were also tested to determine their “openness”, along with a Sample F which was prepared as follows:

[0045] Sample F was manufactured according to the instant invention. The fabric was woven in a leno construction using 2250 denier UV-stabilized ELAS-TER® yarns in the warp and a pick of natural Taslan polyester and a pick of 400 denier ELAS-TER® in each shed of the fill. The fabric was heat set according to the instant invention to melt the ELAS-TER® yarns, to thereby supplementally secure the points of intersection between the warp and fill yarn sets.

[0046] Five areas of each of the fabrics (each area being 45 mm the warp direction and 60 mm in the fill direction) were measured to determine the percent of their total area which constituted open area. The results were then averaged and recorded below. The number of openings per 45 mm×60 mm unit area were also counted by computer, and the average for each of the fabrics was calculated. The results are set forth in the tables below: 4 Sample B C D F Openness Test-Percent Openness of Total Area Area #1 18.7% 36.9% 44.2%   40% Area #2 19.3% 37.3% 47.8% 39.6% Area #3   18% 37.4% 48.9% 41.1% Area #4 19.7% 39.8% 47.9% 41.2% Area #5 19.4% 40.1% 48.1% 42.5% Average 19.2% 38.3% 47.4% 40.1% Number of Openings Per Unit Area Area #1 896 316 488 324 Area #2 974 312 488 342 Area #3 953 320 475 334 Area #4 985 298 482 329 Area #5 996 309 484 322 Average 960.8 311 483.4 330.2

[0047] As noted, the fabrics of the invention described have at least about 15% open area, more preferably at least about 30%, even more preferably at least about 35%, and even more preferably at least about 40%. Furthermore, fabrics having at least about 45% open area can be produced and as indicated by Sample D, have desirably strength levels to enable their use in a variety of end use products.

[0048] In contrast, a typical barathea fabric (similar to that described in commonly-assigned U.S. Pat. No. 5,856,249 described above) would only have about 5% openness, rather than the significant openness achieved with the fabrics of the instant invention. As noted above, this high amount of openness enhances the comfort characteristics of the fabric, as well as providing a desirable aesthetic appearance. In addition, despite their high degree of openness, the fabrics have good strength and dimensional stability, as evidenced by the Yarn Unravel Test and other strength tests described above.

[0049] In the specification there has been set forth a preferred embodiment of the invention, and although specific terms are employed they are used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention being defined in the claims.

Claims

1. A textile fabric comprising:

a woven fabric having a warp yarn set and a weft yarn set, and in which at least a plurality of the yarns forming the warp yarn set are woven in a leno configuration such that said warp yarns are secured about yarns of the weft yarn set, said fabric comprising at least about 15% open area and exhibiting at least about 0.5 pounds strength in each of the warp and weft directions when subjected to a yarn unravel test.

2. A textile fabric according to claim 1, wherein said fabric exhibits at least about 2 pounds strength in the warp direction and at least about 1 pound strength in the weft direction when subjected to a yarn unravel test.

3. A textile fabric according to claim 1, wherein said fabric comprises at least about 35% open area.

4. A textile fabric according to claim 1, wherein said fabric comprises at least about 45% open area.

5. A textile fabric according to claim 1, wherein at least one of said warp and weft yarn sets comprises elastomeric synthetic yarns.

6. A textile fabric according to claim 5, wherein said elastomeric synthetic yarns are resistant to UV irradiation such that said fabric retains at least about 50% of its initial breaking strength when measured in the elastomeric synthetic yarn direction following accelerated exposure to 225 kilojoules of UV irradiation.

7. A textile fabric according to Clam 6, wherein said elastomeric yarns are resistant to UV irradiation such that said fabric retains at least about 70% of its initial breaking strength when measured in the elastomeric synthetic yarn direction following accelerated exposure to 225 kilojoules of UV irradiation.

8. A textile fabric according to claim 5, wherein said elastomeric synthetic yarns are characterized by an elongation at break of at least about 90% and retain at least about 80% of their tensile strength following accelerated exposure to 488 kilojoules of UV irradiation.

9. A textile fabric according to claim 5, wherein said elastomeric synthetic yarns comprise at least about 40% by weight of the fabric.

10. A textile fabric according to claim 1, wherein at least some of the intersections of the yarns of the warp and weft yarn sets are bonded together.

11. A textile fabric according to claim 10, wherein at least one of said warp and weft yarn sets comprises bicomponent sheath/core elastomeric yarns and said sheath component is melted to bond intersections of the yarns of said warp and weft yarn sets.

12. A textile fabric comprising:

a first yarn set interwoven with a second yarn set in a leno configuration, wherein at least one of said first and second yarn sets comprises elastomeric synthetic yarns and said elastomeric synthetic yarns are bonded to yarns of the other of said yarn sets to provide a fabric having high dimensional stability.

13. A textile fabric according to claim 12, wherein said first and second yarn sets are woven together to form an open fabric having at least about 15% open space.

14. A textile fabric according to claim 12, wherein said first and second yarn sets are woven together to form an open fabric having at least about 35% open space.

15. A textile fabric according to claim 12, wherein said first and second yarn sets are woven together to form an open fabric having at least about 45% open space.

16. A textile fabric according to claim 12, wherein said elastomeric synthetic yarns comprise at least about 40% by weight of the fabric.

17. A textile fabric according to claim 12, wherein said elastomeric synthetic yarns comprise a sheath/core bicomponent filament, and said elastomeric synthetic yarns are bonded to yarns of the other of said yarn sets by melt bonding of the bicomponent filament.

18. A textile fabric according to claim 12, wherein said fabric retains at least about 50% of its initial breaking strength when measured in the elastomeric synthetic yarn direction following accelerated exposure to 225 kilojoules of UV irradiation.

19. A textile fabric according to claim 18, wherein said fabric retains at least about 70% of its initial breaking strength when measured in the elastomeric synthetic yarn direction following accelerated exposure to 225 kilojoules of UV irradiation.

20. A textile fabric according to claim 18, wherein said fabric retains at least about 50% of its initial breaking strength when measured perpendicular to the elastomeric synthetic yarn direction following accelerated exposure to 225 kilojoules of UV irradiation.

21. A textile fabric according to claim 19, wherein said fabric retains at least about 50% of its initial breaking strength when measured perpendicular to the elastomeric synthetic yarn direction following accelerated exposure to 225 kilojoules of UV irradiation.

22. A textile fabric according to claim 12, wherein said fabric exhibits at least about 0.5 pounds strength in each of the first and second directions when subjected to a yarn unravel test.

23. A textile fabric according to claim 22, wherein said fabric exhibits at least about 2 pounds strength in the first direction and at least about 1 pound strength in the second direction when subjected to a yarn unravel test.

24. A textile fabric according to claim 12, wherein said first direction comprises the warp direction and the second direction comprises the fill direction of the fabric.

25. A textile fabric comprising a first plurality of elastomeric synthetic yarns extending in a first direction interwoven with a second plurality of yarns extending in a second direction generally transverse to said first direction, wherein said elastomeric synthetic yarns running in the first direction comprise at least about 40% by weight of the fabric and said elastomeric synthetic yarns are characterized by an elongation at break of at least about 90% and retain at least about 80% of their tensile strength following accelerated exposure to 488 kilojoules of UV irradiation, and wherein said first and second plurality of yarns are interwoven in a leno configuration.

26. A textile fabric according to claim 25, wherein said first and second pluralities of yarns are woven together to form an open fabric having at least about 15% open space.

27. A textile fabric according to claim 25, wherein said first and second pluralities of yarns are woven together to form an open fabric having at least about 35% open space.

28. A textile fabric according to claim 25, wherein said first and second pluralities of yarns are woven together to form an open fabric having at least about 45% open space.

29. A textile fabric according to claim 25, wherein said first and second plurality of yarns are woven to define a plurality of yarn intersections, and at least some of said yarn intersections are bonded together.

30. A textile fabric according to claim 25, wherein said elastomeric synthetic yarns are bicomponent sheath/core elastomeric yarns having a sheath component which has a melt temperature that is at least about 30° F. below the melting point of the core component.

31. A textile fabric according to claim 30, wherein portions of the bicomponent sheath/core elastomeric yarns are meltbonded to the second plurality of yarns to form a plurality of bonded yarn intersections.

32. A textile fabric according to claim 25, wherein said fabric retains at least about 50% of its initial breaking strength when measured in the elastomeric synthetic yarn direction following accelerated exposure to 225 kilojoules of UV irradiation.

33. A textile fabric according to claim 32, wherein said fabric retains at least about 70% of its initial breaking strength when measured in the elastomeric synthetic yarn direction following accelerated exposure to 225 kilojoules of UV irradiation.

34. A textile fabric according to claim 32, wherein said fabric retains at least about 50% of its initial breaking strength when measured perpendicular to the elastomeric synthetic yarn direction following accelerated exposure to 225 kilojoules of UV irradiation.

35. A textile fabric according to claim 25, wherein said fabric exhibits at least about 0.5 pounds strength in each of the first and second directions when subjected to a yarn unravel test.

36. A textile fabric according to claim 35, wherein said fabric exhibits at least about 2 pounds strength in the first direction and at least about 1 pound strength in the second direction when subjected to a yarn unravel test.

37. A textile fabric according to claim 25, wherein said first direction comprises the warp direction and the second direction comprises the fill direction of the fabric.