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Abstract

A method of making a polypropylene base fabric for outdoor use, and the fabric so produced, results in an outdoor use product (such as a furniture cover) having high mechanical durability, improved hand, excellent color durability, and lower soiling than comparable conventional products. The method is practiced using yarn comprising or consisting of polypropylene, UV inhibitor, and fluorochemical by: weaving the yarn using heavier yarn in the warp direction and finer yarn in the filling direction, or yarns of substantially equal size or denier in the warp and filling directions, to produce a fabric with a face, a center, and a back, with at least 50% (e.g. about 50-70%) of the filling yarn exposed to the fabric face (and for example about 6-10% in the center and about 20-40% in the back); washing the fabric with detergent and water to scour off the spin finish on the yarns; and drying the washed fabric at a temperature below the softening point of polypropylene (e.g. about 270-280.degree. F.) using air flow and tension control (e.g. an air flow of between about 4,000-5,100 cfm, and a tenter frame). The fabric produced has a shear stiffness of comparable to less than 3.0 gf/cm*Degrees, and an overall flexural rigidity of comparable to less than 600, for a fabric having a weight of about 6.5 oz/sq. yd. The fabric typically has a weight between about 6-7 ounces per square yard, and has a warp tear strength, pursuant to ASTM D117, of greater than 90, and a filling tear strength of greater than 26.

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First Claim