Note: Descriptions are shown in the official language in which they were submitted.
CA 02902325 2015-08-28
08928499CA
WATERPROOF AND UV-RESISTANT FORM-FITTING COVER
MADE OF STRETCHABLE FABRIC
TECHNICAL FIELD
[0001] The present invention relates generally to protective stretchable
covers
and, in particular, to protective covers made of a stretchable fabric.
BACKGROUND
[0002] 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.
[0003] Although covers made of stretchable fabric are known in the art,
there
remains a need for an improved cover made of a stretchable fabric.
SUMMARY
[0004] 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.
[0005] 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.
[0006] 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.
-1-
CA 02902325 2015-08-28
08928499CA
[0007] 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.
[0008] 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.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] 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:
[0010] FIG. 1
depicts a stretchable fabric for use in a protective cover in
accordance with an embodiment of the present invention;
[0011] FIG. 2 depicts an object to be covered;
[0012] FIG. 3
depicts the object covered by a protective cover in accordance
with an embodiment of the present invention;
[0013] FIG. 4 depicts, as an example, a boat covered by a protective cover;
[0014] FIG. 5
depicts, as an example, a wheel and tire covered by a protective
cover;
[0015] FIG. 6
depicts a system for manufacturing covers in accordance with
another embodiment of the present invention; and
[0016] FIG. 7 is a flowchart of a method of manufacturing covers.
-2-
CA 02902325 2015-08-28
08928499CA
[0017] It will be noted that throughout the appended drawings, like
features are
identified by like reference numerals.
DETAILED DESCRIPTION
[0018] 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.
[0019] Disclosed herein are a stretchable cover, a method of manufacturing
the
stretchable cover and a system for manufacturing the stretchable cover.
[0020] STRETCHABLE COVER
[0021] FIG. 1 depicts a fabric for use in a protective cover. The fabric is
generally designated by reference numeral 10. The cover is made of a
stretchable
fabric cut such that the shape of the unstretched fabric is 60-80% of the
shape of the
object to be covered. In accordance with an embodiment of the present
invention,
a polyurethane film is laminated onto the four-way stretch fabric to provide
UV
protection and waterproofing.
[0022] 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 0.55mm. 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
-3-
CA 02902325 2015-08-28
08928499CA
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.
[0023] 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.
[0024] 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.
[0025] 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
-4-
CA 02902325 2015-08-28
=
08928499CA
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.
[0026] FIG. 2 shows an object 20 having an arbitrary shape. The
object's shape
may have any geometry or may be composed of multiple joined or connected
shapes.
[0027] FIG. 3 shows a stretchable protective cover 30 fitted over the
object. The
fabric clings to the object by virtue of its elasticity. No coupling device is
required.
In other embodiments, though, a coupling device may be used to further secure
the
cover to the object. The coupling device may be a hook and loop fastening
system,
a zipper, grommets, rope through loops, hooks through holes, magnets, straps,
clips, belts, snaps, or any combination thereof.
[0028] FIG. 4 shows an example of a stretchable protective cover 40
for a boat.
The waterproof fabric acts as a membrane to keep rain, snow, etc. from
entering the
boat. The UV-resistance also protects the hull of the boat.
[0029] FIG. 5 shows an example of a stretchable protective cover 50
for a wheel
and tire. In some embodiments, the cover may be printed to display a logo,
advertisement or other graphics and/or text.
[0030] 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.
[0031] 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,
-5-
CA 02902325 2015-08-28
08928499CA
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.
[0032] 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.
[0033] SYSTEM AND METHOD OF MANUFACTURING A STRETCHABLE
COVER
[0034] Another
aspect of the present invention is a system and method of
manufacturing a stretchable cover.
[0035] 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.
[0036] One
example of a novel manufacturing system is illustrated in FIG. 6. As
shown by way of example in this figure, the system 100 receives an electronic
order
-6-
CA 02902325 2015-08-28
08928499CA
sent from a user's networked computer 110 operated by a user or customer 120.
The electronic order is communicated through the Internet 130 to the remote
system
100. The system 100 has a computer (or server) having a processor and memory
and communication port (e.g. modem) for receiving the electronic order. The
computer 140 may have an external database for storing material
specifications,
blend specifications, inventory lists, prices, delivery times and costs, or
other such
information. The system 100 includes a fabric cutter 150, e.g. a laser cutter
or other
cutting apparatus. The cutter is controlled by commands or signals from the
computer. The system 100 may also include a stitching machine 160 controlled
by
commands or signals from the computer. The electronic order may include
digital
photographs of the object to be covered. The user may take these photos using
a
digital camera 112 and upload these to the computer 110 by wired or wireless
connection. The
electronic order may include dimensions of the object to be
covered, e.g. length (L), width (W) and height (H). The
system 100 may also
include a billing module and/or a packaging machine.
[0037] The
novel method is summarized in general terms in the flowchart of FIG.
7. As depicted in this flowchart, the method include an initial step 200 of
receiving
an electronic order specifying a size and shape for the cover. The method then
includes a subsequent step 210 of determining a material and blend based on
the
size and shape and a step 220 of computing a fabric size. The method then
involves a further step 230 of cutting a four-way stretchable fabric to an
unstretched
shape corresponding to the object to be covered. The fabric may then be
stitched
as part of the finishing of the stretchable cover.
[0038] 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.
[0039] 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
-7-
CA 02902325 2015-08-28
08928499CA
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.
[0040] 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.
-8-
