Abstract:
An elastomeric mesh fabric with weft strands interwoven with warp threads with the goal of imparting reduced wear on clothing and other articles in contact therewith. Each warp thread has first and second elastomeric helically wound strands, and the band-shaped weft strands comprise a resilient yarn. The weft strands are disposed in alternating first and second patterns that minimize contact area between the weft strands and clothing and other articles. Seat backs, seat bottoms, and other furniture components can be formed by retaining the elastomeric mesh fabric relative to frameworks.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates generally to fabrics. More particularly, disclosed herein is an elastomeric mesh fabric for furniture and other applications intended to impart reduced wear on articles, such as clothing worn by a furniture user, in contact therewith. 
       BACKGROUND OF THE INVENTION 
       [0002]    Resilient mesh has become an increasingly common fabric for use in seating and other applications. In furniture applications, the mesh is typically retained under tension by a peripheral framework. Mesh retained in such a manner has been employed as the sole support surface and in combination with subsidiary support surfaces in back, seat, and other furniture components. The present inventor has contributed to this art with a plurality of inventions, including the Elastomeric Material Application System disclosed in U.S. Pat. No. 6,996,895, the Methods and Arrangements for Securing Fabric of U.S. Pat. No. 7,251,917, and Post-Assembly Tension Adjustment in Elastomeric Material Applications as taught by U.S. Pat. No. 7,517,024 with each of these being incorporated herein by reference. 
         [0003]    The use of resilient mesh in furniture support applications has been found to be advantageous for a number of reasons. In addition to the modern and clean appearance that mesh support panels provide, mesh is advantageous for its breathability. Resilient mesh also reduces zones of discomfort and excess pressure. Moreover, resilient mesh can be retained and potentially adjusted to have varied degrees of tension thereby to provide varied degrees of support for different areas of a person&#39;s body. 
         [0004]    The structure of a typical prior art elastomeric mesh panel is shown in  FIGS. 1 ,  2 A and  2 B. The mesh panel, which is indicated generally at  10 , is a woven fabric formed by a series of warp threads  12  interlaced with generally orthogonally disposed weft strands  14 . Each warp thread  12  is commonly formed by helically wound first and second strands  12 A and  12 B, which are normally formed from resilient elastomeric material. Each weft strand  14  is normally formed from a resilient yarn, which can be wider than it is thick thereby to have a band shape. As used herein, the term yarn shall be held to mean a plied strand composed of fibers or filaments. The warp threads  12  are separated by a distance a, and the weft strands  14  are separated by a distance b. 
         [0005]    The weft strand  14  in this prior art arrangement is woven through the first and second strands  12 A and  12 B of each warp thread  12  as shown in  FIG. 2B . The mesh panel  10  can be considered to have an occupant side facing the furniture user and the material of the user&#39;s clothing and an opposite side facing away from the occupant. The weft strand  14  is woven through the strands  12 A and  12 B to have flat portions alternatingly disposed to the occupant side and then to the opposite side of the mesh panel  10 . The flat portions are generally coplanar with the mesh panel  10  when the panel  10  is flat. Under this arrangement, flat portions M of the weft strand  14  will face the furniture occupant and the material of the occupant&#39;s clothing, and flat portions O will face away from the furniture occupant. 
         [0006]    Both ends of each flat portion M and O pass from the same side of the mesh panel  10  between the strands  12 A and  12 B. With this, depending on the side to which the flat portion M or O is disposed, both ends of each flat portion M or O will either pass from the material side to the opposite side or vice versa. Adjacent weft strands  14  are identically configured but staggered so that where one strand  14  has a flat portion M to the material side of the panel  10  the adjacent strands  14  will have flat portions O to the opposite side of the panel  10  and vice versa. Under this configuration, aside from the portions passing between the strands  12 A and  12 B, roughly half of each weft strand  14  is disposed to the material side of the panel  10 . 
         [0007]    While advantageous for multiple reasons, a significant problem exhibited by resilient mesh has come to be recognized by the present inventor, namely, that the structure of the elastomeric mesh typical of the prior art undesirably acts as a mechanism for pulling, chewing, and tearing fibers away from the occupant&#39;s clothing. What is theorized is that the yarn forming the weft strands  14 , which stretch when pressure is applied thereto, act much like tweezers to extract fibers from the occupant&#39;s clothing. As the weft strands  14  are stretched, their constituent fibers transform from being more generally unaligned and haphazardly disposed to a greater degree of alignment thereby potentially pinching and retaining fibers from the occupant&#39;s clothing. Consequently, an expensive suit can become haggard and worn by repeated exposure to mesh panels  10  so constructed. 
         [0008]    This harm to the furniture user&#39;s clothing can readily be appreciated by reference to the opposite side of a mesh support surface chair that has been used for a significant period of time. Having further reference to  FIG. 3 , for example, a mesh panel  10  is retained in tension relative to a framework  100 . There, fibers  102  that have been removed from the seat occupant&#39;s clothing have accumulated on the opposite side of the mesh panel  10  giving a clear indication of the wear and damage caused by the ‘chewing’ phenomenon exhibited by the mesh panel  10 . 
         [0009]    Advantageously, the present inventor has appreciated that the large surface area in contact with the occupant&#39;s clothing and the flat orientation of the weft strands  14  relative to the occupant&#39;s clothing contribute to the pulling and tearing effect. With the relatively large surface area of the flat portions M of the weft strands  14  contacting the occupant&#39;s clothing, a greater number of fibers are vulnerable to being ripped therefrom and a more efficient ‘chewing’ action is achieved. Based on this appreciation and knowledge, the present inventor has discovered that it would be advantageous to minimize the surface area of the yarn or weft strands  14  that is in direct and flat contact with an occupant&#39;s clothing while still exploiting the advantageous characteristics that elastomeric mesh fabric can provide. 
       SUMMARY OF THE INVENTION 
       [0010]    Accordingly, the present invention is founded on the basic object of providing a mesh fabric that imparts less wear on material in contact therewith. 
         [0011]    An underlying object of the invention is to provide a mesh fabric with yarn strands that exhibit reduced surface contact with material in contact therewith. 
         [0012]    These and further objects and advantages of the present invention will become obvious not only to one who reviews the present specification and drawings but also to those who have an opportunity to experience an embodiment of the mesh fabric disclosed herein. However, it will be appreciated that, although the accomplishment of each of the foregoing objects in a single embodiment of the invention may be possible and indeed preferred, not all embodiments will seek or need to accomplish each and every potential advantage and function. Nonetheless, all such embodiments should be considered within the scope of the present invention. 
         [0013]    In carrying forth these objects, an elastomeric mesh according to the invention has weft strands interwoven with warp threads with each warp thread comprising first and second elastomeric strands and the weft strands comprising a resilient yarn. When the mesh fabric is viewed in cross section, at least some of the weft strands are disposed in a first pattern with a series of portions that trough below the rightwardly disposed strand of each warp thread, rise to a crest atop the leftwardly disposed strand of the adjacent warp thread, and then fall in a downturned face that passes between the leftward and rightward strands of that adjacent warp thread. At least some of the weft strands can be disposed in a second pattern with a series of portions that trough below the leftwardly disposed strand of each warp thread, rise to a crest atop the rightwardly disposed strand of the adjacent warp thread, and then fall in a downturned face that passes between the leftward and rightward strands of that adjacent warp thread. 
         [0014]    The first and second patterns can be disposed in alternation to contribute to directional stability in the elastomeric mesh fabric, and the first and second strands of the warp threads can be helically wound. In one such embodiment, the first and second strands can cross over one another once between each weft strand. Moreover, the weft strands can have a width and a thickness with the width being greater than the thickness such that the weft strands have a band shape. 
         [0015]    A component of an article of furniture can thus be formed with an elastomeric mesh fabric as disclosed herein retained relative to a framework. Many furniture and other components are possible and within the scope of the present invention except as it might be expressly limited. By way of example, the component of the article of furniture can comprise a seat back, a seat bottom, or some other portion of an article. 
         [0016]    One will appreciate that the foregoing discussion broadly outlines the more important goals and features of the invention to enable a better understanding of the detailed description that follows and to instill a better appreciation of the inventor&#39;s contribution to the art. Before any particular embodiment or aspect thereof is explained in detail, it must be made clear that the following details of construction and illustrations of inventive concepts are mere examples of the many possible manifestations of the invention. 
     
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         [0017]    In the accompanying drawing figures: 
           [0018]      FIG. 1  is a view in front elevation of a panel of elastomeric mesh under the prior art; 
           [0019]      FIG. 2A  is a magnified view in front elevation of a portion of a panel of elastomeric mesh as taught by the prior art; 
           [0020]      FIG. 2B  is a cross-sectional view of the panel of elastomeric mesh pursuant to the prior art of  FIG. 2A  taken along the line  2 B- 2 B; 
           [0021]      FIG. 3  is a perspective view of a panel of prior art elastomeric mesh applied to a seat back structure after a period of use; 
           [0022]      FIG. 4A  is a magnified view in front elevation of a portion of a panel of elastomeric mesh according to the present invention; 
           [0023]      FIGS. 4B and 4C  are cross-sectional views of the panel of elastomeric mesh of  FIG. 4A  taken along the lines  4 B- 4 B and  4 C- 4 C; 
           [0024]      FIG. 5  is a perspective view of a panel of elastomeric mesh applied to a seat back structure after a period of use depicting the desired resultant benefits of the invention; and 
           [0025]      FIG. 6  is a perspective view of panels of elastomeric mesh applied to a seat back structure and a seat bottom structure. 
       
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
       [0026]    The mesh fabric disclosed herein is subject to a wide variety of embodiments. However, to ensure that one skilled in the art will be able to understand and, in appropriate cases, practice the present invention, certain preferred embodiments of the broader invention revealed herein are described below and shown in the accompanying drawing figures. Therefore, before any particular embodiment of the invention is explained in detail, it must be made clear that the following details of construction and illustrations of inventive concepts are mere examples of the many possible manifestations of the elastomeric mesh taught herein. 
         [0027]    Turning more particularly to the drawings, an elastomeric mesh panel according to the present invention is indicated generally at  10  in  FIG. 4A  and then in first and second cross sections in  FIGS. 4B and 4C . There, the elastomeric mesh  10  again comprises a woven fabric formed by a series of warp threads  12  interwoven with generally perpendicularly disposed weft strands  14 . Each warp thread  12  is formed by helically wound first and second strands  12 A and  12 B. The strands  12 A and  12 B can be formed from a resilient material, such as an elastomer. Each strand  12 A and  12 B can be formed as a single elastomeric strand or of multiple elastomeric strands, which may or may not be interwoven. Each weft strand  14  can be formed from a resilient yarn, which can be wider than it is thick thereby to have a band shape. The warp threads  12  are again separated by a distance a, and the weft strands  14  are again separated by a distance b. 
         [0028]    The weft strand  14  is woven through the first and second strands  12 A and  12 B of each warp thread  12  in the alternating patterns shown in  FIGS. 4B and 4C . In the first pattern as depicted in  FIG. 4B , the weft strand  14  is disposed in what may be considered a rolling wave configuration in a first direction, which is left to right in the drawing when the mesh panel  10  is viewed in cross section, with a series of left-to-right inclined portions that trough below the rightwardly disposed strand of each warp thread  12 , rise to a crest atop the leftwardly disposed strand of the next warp thread  12 , and then fall in a downturned face that passes between the leftward and rightward strands of that next warp thread  12 . 
         [0029]    In the second pattern as depicted in  FIG. 4C , the weft strand  14  is disposed in a rolling wave configuration in a second direction, which is right to left in the drawing again when the mesh panel  10  is viewed in cross section, with a series of right-to-left inclined portions that trough below the leftwardly disposed strand of each warp thread  12 , rise to a crest atop the rightwardly disposed strand of the next warp thread  12 , and then fall in a downturned face that passes between the leftward and rightward strands of that next warp thread. 
         [0030]    In this embodiment, the first and second strands  12 A and  12 B of the warp threads  12  are helically wound with the strands  12 A and  12 B passing over one another once between each weft strand  14 . As a result, the first strand  12 A will be the leftward strand in one row of the weft strand  14 , but it will be the rightward strand in the adjacent row of the weft strand  14 . The first and second patterns are disposed in alternation to maintain directional stability in the elastomeric mesh panel  10  and to ensure consistent performance of the mesh panel  10 . 
         [0031]    Under this arrangement, it will be appreciated that, although roughly half of the weft strand  14  will continue to face the user of the furniture, the great majority of the weft strand  14  would tend to be spaced from direct contact with the furniture occupant and the material of the furniture occupant&#39;s clothing. Only the portions M will tend to be in a plane of direct contact with the clothing of a furniture occupant or other contacting material. The remaining portions of the weft strand  14  are angled relative to and spaced from the opposed surfaces of the mesh panel  10 . With this, the angled and spaced portions of the weft strand  14  will be less efficient in ‘chewing’ fibers from a furniture occupant&#39;s clothing or other material, and that material will tend to exhibit less wear and damage through contact with the mesh panel  10 . 
         [0032]    As shown in  FIG. 5 , a mesh panel  10  according to the invention retained relative to a framework  100  would ideally pull and tear fewer fibers from the material of a user&#39;s clothing. As a result, fewer fibers will be accumulated, and the clothing will suffer less damage over time. As described in the present inventor&#39;s U.S. Pat. No. 6,996,895, U.S. Pat. No. 7,251,917, and U.S. Pat. No. 7,517,024, which are incorporated herein by reference, the framework  100  and the retained mesh panel  10  could take the form of a wide variety of furniture and other components. By way of example as seen in  FIG. 6 , a framework  100  and a mesh panel  10  could form a seat back  102 , a seat bottom  104 , or some other component of an article of furniture. 
         [0033]    With certain details and embodiments of a mesh fabric  10  according to the present invention disclosed, it will be appreciated by one skilled in the art that changes and additions could be made thereto without deviating from the spirit or scope of the invention. This is particularly true when one bears in mind that the presently preferred embodiments merely exemplify the broader invention revealed herein. Accordingly, it will be clear that those with certain major features of the invention in mind could craft embodiments that incorporate those major features while not incorporating all of the features included in the preferred embodiments. 
         [0034]    Therefore, the following claims are intended to define the scope of protection to be afforded to the inventor. Those claims shall be deemed to include equivalent constructions insofar as they do not depart from the spirit and scope of the invention. It must be further noted that a plurality of the following claims may express certain elements as means for performing a specific function, at times without the recital of structure or material. As the law demands, these claims shall be construed to cover not only the corresponding structure and material expressly described in this specification but also all equivalents thereof that might be now known or hereafter discovered.