Double layer woven fabric

Abstract

A double layer woven fabric for use in various applications, including recreational applications such as pool covers. The fabric is formed by two layers of yarns secured together. At least one layer (and, in one embodiment, both layers) of yarns comprises at least two types of yarn of differing geometrical shapes that are preferably positioned alternately across the fabric. The yarns of one shape help to block sunlight while the yarns of the other shape help to ensure that open channels are formed through the fabric for water flow.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view of one embodiment of the fabric of this invention.

DETAILED DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates one embodiment of the fabric of this invention. The fabric 10 includes two layers 12, 14 of weft or fill yarns 16 that are woven together with warp yarn 18. Note, however, that layers 12, 14 could be oriented in the warp direction and yarn 18 could be oriented in the weft direction. At least one layer 12, 14 of yarns 16 (and, in the embodiment disclosed in FIG. 1, both layers 12, 14 of yarns 16) comprises two types of yarn 20, 22 of differing geometrical shapes that are preferably positioned alternately across the fabric. As shown in FIG. 1, the first yarn 20 is preferably but not necessarily a tape yarn in that has a rectilinear cross-section with a width greater than its thickness. One thousand (1000) denier to 2900 denier fibrillated tape is particularly useful in this application, with 1500 denier fibrillated tape being the most preferable. The second yarn 22 is preferably but not necessarily a monofilament yarn having a different geometrically-shaped cross-section than first yarn 20. In this embodiment, second yarn 22 has a substantially rounded cross-sectional shape, such as a substantially circular cross-sectional shape shown in FIG. 1. However, as explained in more detail below, second yarn 22 can be of any shape that prevents the two layers 12, 14 from lying directly adjacent to each other along their entire lengths but rather ensures that a gap 30 is maintained between the two layers 12, 14 at least at certain points along the fabric length. Four hundred (400) denier to 1600 denier monofilament yarn is preferable for the second yarn 22.

Moreover, as shown in FIG. 1, the first and second yarns 20, 22 in layer 12 are preferably offset from the first and second yarns 20, 22 in layer 14 so that, when layers 12, 14 are woven together, a first yarn 20 in layer 12 is primarily adjacent to a second yarn 22 in layer 14.

The two layers 12, 14 are preferably woven together with yarn 18. The yarn 18 is preferably, but does not have to be, 400 denier to 1500 denier monofilament yarn. All of the yarns used in fabric 10 are preferably, but do not have to be, made from synthetic polymers and more preferably from polypropylene. While the density of the fabric will depend on its intended properties and uses, the fabric in the warp direction preferably has a density of 20 to 50 threads/inch, and the fabric in the fill or weft direction preferably has a density of 15 to 40 threads/inch.

The resulting fabric 10 may be, but does not have to be, subjected to a calendaring process whereby the fabric 10 is subjected to heat and pressure (such as by running the fabric through a set of heated rollers) to compress and/or flatten yarns 16, 18 and thereby reduce the overall thickness of fabric 10.

The double layer structure of fabric 10 forms essentially a solid sheet of fibers that prevent at least, and preferably more than, 99% of light from passing through the fabric 10 while providing open channels 24 through the fabric 10 for water flow. Any test that accurately measures the amount of light transmitted through fabric 10 may be employed to determine light penetration and resulting shade percentage. For example, a shade box provided with a light source at one end and a light meter at the other end may be used. The fabric to be tested is positioned between the light source and meter, the light source is activated, and the light meter measures the amount of light (R) that penetrates through the fabric and reaches the meter. The amount of shade that the fabric affords can then be calculated based on that measurement (% Shade=100−R). U.S. Pat. No. 5,651,641, the entirety of which is herein incorporated by reference, discloses detailed specifications for measuring light penetration.

As illustrated in FIG. 1, sun rays 26, 28 travel in substantially straight lines. The wider tape yarns 20 provided on the fabric 10 deflect the sun rays. To the extent that a sun ray 28 is not deflected by a tape yarn 20 in the upper layer 12 of the fabric 10 (such as sun ray 28), then a tape yarn 20 in the lower layer 14 of the fabric 10 will deflect the ray 28 and thereby prevent light from penetrating through the fabric 10 to the water underneath.

Moreover, the different geometrical shapes of the yarns 20, 22 forming the fabric 10 create open channels 24 for water to flow through the fabric 10. More specifically, the substantially circular shape and size of second yarns 22 ensure that a gap 30 is maintained between the two layers 12, 14. Open channels 24 through which water can flow extend between adjacent yarns 16 in each layer 12, 14 and through the gap 30 between the layers 12, 14. With this double layer fabric construction, water is able to flow at a rate between 5-75 gallons per square foot per minute through the fabric 10, as measured by ASTM standard D4491-99A.

The foregoing is provided for the purpose of illustrating, explaining and describing embodiments of the present invention. Further modifications and adaptations to these embodiments will be apparent to those skilled in the art and may be made without departing from the spirit of the invention or the scope of the following claims.

Claims

1. A fabric comprising a first layer of yarns woven to a second layer of yarns, wherein the first layer comprises a plurality of first yarns and a plurality of second yarns, each of the first and second yarns having a cross-sectional shape, wherein the cross-sectional shape of the first yarns of the first layer is different from the cross-sectional shape of the second yarns of the first layer.

2. The fabric of claim 1, wherein channels extend through the fabric between the first and second layers.

3. The fabric of claim 2, wherein water is capable of flowing through the channels of the fabric at a rate between five to seventy-five gallons per square foot per minute.

4. The fabric of claim 1, wherein the fabric prevents at least approximately 99% of light from passing through the fabric.

5. The fabric of claim 1, wherein the first yarns and the second yarns of the first layer alternate across a width of the fabric.

6. The fabric of claim 1, wherein the cross-sectional shape of the first yarns of the first layer is substantially rectilinear.

7. The fabric of claim 6, wherein the first yarns of the first layer comprise fibrillated tape.

8. The fabric of claim 1, wherein the cross-sectional shape of the second yarns of the first layer is substantially rounded.

9. The fabric of claim 8, wherein the cross-sectional shape of the second yarns of the first layer is substantially circular.

10. The fabric of claim 1, wherein the second layer of yarns comprises a plurality of first yarns and a plurality of second yarns, each of the first and second yarns of the second layer having a cross-sectional shape, wherein the cross-sectional shape of the first yarns of the second layer is different from the cross-sectional shape of the second yarns of the second layer.

11. The fabric of claim 10, wherein the first yarns and the second yarns of the second layer alternate across a width of the fabric.

12. The fabric of claim 10, wherein the cross-sectional shape of the first yarns of the second layer is substantially rectilinear.

13. The fabric of claim 12, wherein the first yarns of the second layer comprise fibrillated tape.

14. The fabric of claim 10, wherein the cross-sectional shape of the second yarns of the second layer is substantially rounded.

15. The fabric of claim 14, wherein the cross-sectional shape of the second yarns of the second layer is substantially circular.

16. The fabric of claim 10, wherein: the cross-sectional shape of the first yarns of the first and second layers is substantially rectilinear;the cross-sectional shape of the second yarns of the first and second layers is substantially rounded;the first and second yarns of the first layer alternate across a width of the fabric; andthe first and second yarns of the second layer alternate across the width of the fabric.

17. The fabric of claim 16, wherein at least some of the first yarns of the first layer are substantially adjacent to at least some of the second yarns of the second layer.

18. The fabric of claim 16, wherein at least some of the second yarns of the first layer are substantially adjacent to at least some of the first yarns of the second layer.

19. A pool cover comprising the fabric of claim 1.

20. A fabric comprising a first layer of yarns woven to a second layer of yarns, wherein: the first layer comprises a plurality of first yarns and a plurality of second yarns, each of the first and second yarns of the first layer having a cross-sectional shape;the second layer comprises a plurality of first yarns and a plurality of second yarns, each of the first and second yarns of the second layer having a cross-sectional shape;the cross-sectional shape of the first yarns of the first and second layers is substantially rectilinear;the cross-sectional shape of the second yarns of the first and second layers is substantially rounded;the first and second yarns of the first layer alternate across a width of the fabric;the first and second yarns of the second layer alternate across the width of the fabric;at least some of the first yarns of the first layer are substantially adjacent to at least some of the second yarns of the second layer;at least some of the second yarns of the first layer are substantially adjacent to at least some of the first yarns of the second layer; anda plurality of channels extend through the fabric between the first and second layers of yarns.

21. The fabric of claim 20, wherein water is capable of flowing through the channels of the fabric at a rate between five to seventy-five gallons per square foot per minute.

22. The fabric of claim 20, wherein the fabric prevents at least approximately 99% of light from passing through the fabric.

23. A method for making a fabric, the method comprising: a. providing a first layer of yarns, wherein the first layer comprises a plurality of first yarns and a plurality of second yarns, each of the first and second yarns having a cross-sectional shape, wherein the cross-sectional shape of the first yarns is different from the cross-sectional shape of the second yarns;b. providing a second layer of yarns; andc. weaving the first and second layer of yarns together.

24. The method of claim 23, wherein providing a first layer of yarns comprises alternately positioning the first yarns and second yarns of the first layer across a width of the fabric.

25. The method of claim 23, wherein providing the second layer of yarns comprises providing a plurality of first yarns and a plurality of second yarns, each of the first and second yarns having a cross-sectional shape, wherein the cross-sectional shape of the first yarns of the second layer is different from the cross-sectional shape of the second yarns of the second layer.

26. The method of claim 25, wherein providing a second layer of yarns comprises alternately positioning the first yarns and second yarns of the second layer across a width of the fabric.

27. The method of claim 25, wherein weaving the first and second layers of yarn together comprises weaving at least some of the first yarns of the first layer adjacent to at least some of the second yarns of the second layer.

28. The method of claim 25, wherein weaving the first and second layers of yarn together comprises weaving at least some of the second yarns of the first layer adjacent to at least some of the first yarns of the second layer.

29. The method of claim 23, further comprising subjecting the fabric to heat and pressure.

30. The method of claim 23, wherein: (i) providing a first layer of yarns comprises alternately positioning the first yarns and second yarns of the first layer across a width of the fabric;(ii) providing the second layer of yarns comprises: (a) providing a plurality of first yarns and a plurality of second yarns, each of the first and second yarns of the second layer having a cross-sectional shape, wherein the cross-sectional shape of the first yarns of the second layer is different from the cross-sectional shape of the second yarns of the second layer; and(b) alternately positioning the first yarns and second yarns of the second layer across the width of the fabric; and(iii) weaving the first and second layers of yarn together comprises: (a) weaving at least some of the first yarns of the first layer adjacent to at least some of the second yarns of the second layer; and(b) weaving at least some of the second yarns of the first layer adjacent to at least some of the first yarns of the second layer.

31. The method of claim 23, further comprising manufacturing a pool cover with the fabric.