Composite elastomeric yarns

Abstract

Disclosed are composite elastomeric yarns comprising a polymeric core, a thermoplastic polymeric sheath disposed about the core and fibers disposed about and mechanically anchored in the sheath. The melting point temperature of the material comprising the sheath is at least about 10° C. and preferably from about 50° C. to about 75° C. lower than the melting point temperature of the material comprising the core. Methods and articles relating to such yarn are also disclosed.

Description

FIELD OF THE INVENTION [0001] This invention relates to certain composite elastomeric yarns suitable for use in furniture / seating fabrics, methods for making said composite elastomeric yarns and articles incorporating fabrics comprising said composite elastomeric yarns. The composite elastomeric yarns of the present invention are particularly well suited for use in indoor and outdoor furniture fabrics for seats, both bottoms and backs, installed in various forms of ground transportation such as automobiles, motorcycles, trucks, buses, trains, etc., as well as various aircraft and marine craft, where a lightweight combination of strength, comfort and style is desired. BACKGROUND OF THE INVENTION [0002] In the past, elastomeric yarns used to produce fabrics having elastomeric properties have typically included rubber and elastomeric polyurethanes, such as spandex, which possess high coefficients of friction. As a result, they are difficult to handle in typical textile yarn and fabric ...

AI Technical Summary

Benefits of technology

[0011] The method aspects of the present invention comprise the steps of: providing a composite elastomeric yarn comprising a thermoplastic polymeric core and thermoplastic polymeric sheath disposed about the core wherein the melting point temperature of the sheath is at least about 10° C. lower than the melting point temperature of the core; heating the composite elastomeric yarn to a temperature at or above about the melting point temperature of the sheath but below the melting point temperature of the core; disposing fibers in intimate mechanical contact about the sheath; and cooling the composite elastomeric yarn to mechanically anchor said fibers in said sheath. In certain preferred embodiments, the methods further comprise stretching the composite elastomeric yarn from about 10% to about 500% beyond the relaxed state prior to the step of disposing said fibers. This preferred method enhances the ability of the manufacturer to vary the fiber density and / or bulk of the resulting composite yarn.

[0012] The articles of the present invention-relate to furniture fabrics, and particularly to seating fabrics, comprising composite elastomeric yarns for use in seats and backs of chairs, benches and sofas used in office and / or residential environments or installed in various forms of ground transportation such as automobiles, motorcycles, trucks, buses, trains, etc. as well as various aircraft and marine craft. By using fabrics comprising the composite elastomeric yarns in vehicle seating assemblies, a fabric possessing strength, comfort and elasticity can be achieved in combination with superior aesthetic qualities. In certain preferred embodiments, thin profile vehicle seating assemblies can be constructed with fabrics comprising the composite elastomeric yarns without the need for bulky foam cushions, stuffing material, springs or rubber straps while maintaining a desirable combination of support, comfort and appearance.

Problems solved by technology

As a result, they are difficult to handle in typical textile yarn and fabric manufacturing processes and are uncomfortable when in direct contact with the human body.

In such seating assemblies, however, the extensive use of foam cushioning, stuffing material and springs or elastic straps adds significantly to the weight of the finished product which is undesired in vehicle applications where fuel economy is often a goal.

Further, the use of varying combinations of these separate components results in seat assemblies having higher costs of materials and, because of complicated assembly procedures, greater labor costs as well.

While thin profile seats have been developed, they have not provided the aesthetic qualities that are desired in many furniture fabrics.

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