Patent Application
20170058452
The present invention relates generally to protective stretchable covers and, in particular, to protective covers made of a stretchable fabric.
Protective covers made of stretchable fabrics are known in the art. These covers are used to protect various objects from ultraviolet (UV) radiation from the sun, or from rain, snow, ice, wind, dust, or other elements. Breathable fabrics are also used to reduce mildew.
Although covers made of stretchable fabric are known in the art, there remains a need for an improved cover made of a stretchable fabric.
The following presents a simplified summary of some embodiments of the invention in order to provide a basic understanding of the invention. This summary is not an extensive overview of the invention. It is not intended to identify key/critical elements of the invention or to delineate the scope of the invention. Its sole purpose is to present some embodiments of the invention in a simplified form as a prelude to the more detailed description that is presented later.
In general, a protective cover having a stretchable fabric is cut to a size and shape corresponding to an object to be cover such that the unstretched cover represents about 60-80% of the size of the object to be covered.
Accordingly, an inventive aspect of the present disclosure is a waterproof and UV-resistant form-fitting cover comprising a four-way stretchable fabric that is pre-cut to an unstretched shape corresponding to 60-80% of a stretched shape that fits onto an object to be covered by the fabric, wherein the fabric is UV-resistant and waterproof.
Another inventive aspect of the present disclosure is a method of manufacturing a form-fitting cover that includes steps of receiving an electronic order specifying a size and shape for the cover, determining a material and blend based on the size and shape, computing a fabric size, and cutting a four-way stretchable fabric to an unstretched shape corresponding to the object to be covered.
Another inventive aspect of the present disclosure is a system for manufacturing a form-fitting cover. The system includes a communication port for receiving an electronic order specifying a size and shape for the cover, a processor for determining a material and blend based on the size and shape and for computing a fabric size, and a fabric cutter controlled by the processor for cutting a four-way stretchable fabric to an unstretched shape corresponding to the object to be covered.
Further features and advantages of the present technology will become apparent from the following detailed description, taken in combination with the appended drawings, in which:
It will be noted that throughout the appended drawings, like features are identified by like reference numerals.
In the following description, various embodiments of the present invention will be described. For purposes of explanation, specific configurations and details are set forth in order to provide a thorough understanding of the embodiments. However, it will also be apparent to one skilled in the art that the present invention may be practiced without the specific details. Furthermore, well-known features may be omitted or simplified in order not to obscure the embodiment being described.
Disclosed herein are a stretchable cover, a method of manufacturing the stretchable cover and a system for manufacturing the stretchable cover.
Stretchable Cover
The stretchable fabric may be a nylon/spandex fabric having a range of blends. In one specific embodiment of this invention, the protective fabric may be, for example, the Dri Tek 8020 from Eastex Products. This fabric is composed of 78% nylon and 22% spandex (elastane) laminated to 1 mil polyurethane film with a thickness of 0.55 mm. Although a Nylon/Spandex composition of 78% nylon/22% spandex provides excellent elasticity (“stretchability”), it will be appreciated that variations in the composition may still provide excellent results. In one embodiment, the fabric is made of a 45 denier/13 filament dull nylon and a 40 denier spandex. It may optionally have a matte finish. In this embodiment, the fabric stretch is 80-100 weft/162-198 warp, although these stretch properties may vary in other embodiments. It will be recalled that the weft is the term for the thread or yarn which is drawn through the warp yarns to create cloth. Warp is the lengthwise or longitudinal thread in a roll, while weft is the transverse thread. The fabric weight is 5.3 oz/yd in this instance although this too may vary in other embodiments. The 1 mil polyurethane film may be made of an aromatic polyester polyurethane film/sheet having the following physical properties: durometer of 93-95 according to D2240 ASTM, a specific gravity of 1.2 according to D792, a tensile-ultimate strength of L 10 000 according to D882, an elongation-ultimate strength of 650 according to D882, a tear strength of 650 according to D1004. UV Resistance may tested under, or made to comply with, any industry tests e.g. AATCC 16E outdoor color fastness. Waterproofing may be tested as per AATCC 127.
In another embodiment, a blend of 82% nylon and 18% Lycra® spandex may be employed. The Nylon may be a 6,6 Nylon (or 6-6 Nylon) which is a polymer made of hexamethylenediamine and adipic acid. The Lycra fibers have an ultimate extension of about 600%, thus providing excellent stretchability. This blend has a stretchability of approximately 200% lengthwise and 144% widthwise. In other embodiments, the fabric may be 75/25 nylon/spandex, 70/30 nylon spandex, 65/35 nylon spandex or 60/40 nylon/spandex. Different blends and different materials may be used for different applications or uses. The fabric may be chemically treated or coated to have other properties, e.g. fire-resistance, mold-resistance, etc.
Spandex, sometimes sold under the trade name LYCRA®, is a manufactured fiber of a long-chain synthetic polymer containing at least 85 percent segmented polyurethane. The polyurethane is prepared from a polyether glycol, a mixture of diisocyanates, and a chain extender and then melt-spun, dry-spun or wet-spun to form the spandex fiber. Another type of elastomeric yarn is polybutylene-terephtalate (PBT) yarn, a highly elastic, friction-texturized polyester yarn available from Swicofil AG Textile Services of Emmenbruecke, Switzerland.
The fabric is UV-treated and waterproofed (e.g. by laminating a 1 mil waterproof polyurethane film) and then cut to specific dimensions to fit in a form-fitting manner over the object to the protected. For example, for a vehicle cover, the cover may be cut to approximate the shape of the vehicle, i.e. to approximately 70% of the length of the vehicle. The fabric stretches the remaining 30% of the length to fit tautly over the vehicle. This provides a good fit that precludes the cover from being blown off by the wind without stretching the material too much. Since spandex fibers are prone to damage caused by various factors such as heat, light and chlorine, stabilizers such as antioxidants and light stabilizers may be added to protect the fibers.
The covers may be pre-formed (pre-cut) to suit particular shapes of objects to be covered. Some examples of different covers include patio furniture covers, boat covers, boat motor covers, snow machine (snowmobile) covers, motorcycle covers, 4 wheeler (quad) or ATV covers, BBQ covers, air conditioning covers, satellite covers, hot tub covers, car covers, tire covers, equipment covers, trailer covers, tonneau covers, patio covers (over head), swing covers, transport truck covers, tank covers, hay covers, bicycle covers, road sign covers, lumber yard covers, tree stand enclosures, tents, dust control barriers, mining underground covers, trash covers, garden frost covers, wind breaks, etc.
The four-way stretchable waterproof and UV-resistant protective cover may be used for multiple objects. The cover also confers the following benefits or advantages: the cover is compact, very light weight, flexible, form-fitting, re-usable, breathable, user friendly, practical, inexpensive to manufacture, durable and washable. This fabric protects objects exposed to the elements from harmful effects of the sun (UV radiation), rain, snow, sleet, hail, wind, pollen, corrosive airborne substances, mildew, etc.
The product is also environmentally friendly since it reduces the amounts of disposable wraps and covers being put in the garbage. It also helps reduce water usage that would otherwise be needed to clean unprotected objects.
System and Method of Manufacturing a Stretchable Cover
Another aspect of the present invention is a system and method of manufacturing a stretchable cover.
A novel computer-controlled method of manufacturing a stretchable cover involves electronically receiving an electronic customer order for a cover (e.g. by e-mail or by website). The electronic order may formatted to be computer-readable. The order may include dimensions of an object to be covered. The method may be implemented by a computer having a processor and memory and a communication port such as a modem or equivalent. The computer generates computer-aided manufacturing (CAM) commands and sends these commands to a cutting machine (e.g. a laser cutter) to cut the fabric to the desired dimensions. The order may include uploading one or more photographs and key dimensions, e.g. side and front view photos of a vehicle with the length and width of the vehicle from which the computer can calculate other visible dimensions, e.g. the height. The order may specify the object to be covered and/or the intended usage of the cover. The computer can then determine the desired material and/or the desired blend, and may also determine the amount of stretch to provide a desired form-fit on the object and whether features such as waterproofing and UV resistant films are to be added. The order may specify that the cover is to fit multiple similarly sized objects of different shape in which case the computer can determine the optimal cover size, material and blend for the requested multi-use cover.
One example of a novel manufacturing system is illustrated in
The novel method is summarized in general terms in the flowchart of
This method and system enables a stretchable fabric cover to be easily ordered online by a customer. The system can automatically manufacture the cover based on the information contained in the electronic order.
The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. The term “connected” is to be construed as partly or wholly contained within, attached to, or joined together, even if there is something intervening. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate embodiments of the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.
The embodiments of the invention described above are intended to be exemplary only. As will be appreciated by those of ordinary skill in the art, to whom this specification is addressed, many obvious variations, modifications, and refinements can be made to the embodiments presented herein without departing from the inventive concept(s) disclosed herein. The scope of the exclusive right sought by the applicant(s) is therefore intended to be limited solely by the appended claims.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2902325 | Aug 2015 | CA | national |
