Disclosed are a method, a device and/or a system of proliferating a thread count of a woven textile by simultaneous insertion within a single pick insertion event of a loom apparatus multiple adjacent parallel yarns drawn from a multi-pick yarn package. In one or more embodiments, multiple texturized polyester weft yarns of denier between 15 and 65 are wound on a single bobbin in a parallel adjacent fashion such that they may be fed into an air jet pick insertion apparatus and/or a rapier pick insertion apparatus of an air jet loom to weave a textile that has between 90 to 235 ends per inch cotton warp yarns and between 100 and 965 polyester weft yarns.

A process is described wherein pile yarn is woven with cotton weft and warp yarns to produce terry fabrics, such as towels. The fabric is then washed in warm water to dissolve the PVA fibers. The amount of fibers dissolved, depends upon the count of the yarn or yarns used. By dissolving the PVA fibers, a hollow air space is produced throughout the pile yarn, corresponding to an increase in the air space in the pile yarn. By increasing the air space in the pile yarn, the resulting towels are softer and bulkier than standard cotton towels. The present invention further relates to pile yarn in terry woven fabric (warp yarn), or weft yarn, in the case of flat fabrics.

A method includes drawing a roving thread from a roving bobbin through a roving guide, an aft drafting roller, and a mid drafting roller to a front drafting roller, and drawing a spandex core from a spandex bobbin using a guide roller. The method also includes associating the roving thread and the spandex core by drawing the roving thread and the spandex core in an approximately parallel fashion through the front drafting roller, and drawing the associated roving thread and the spandex core through a lappet hook and an anti-ballooning guide. Further, the method includes winding the drawn associated roving thread and the spandex core on a ring-frame bobbin including a ring traveler attached to a rotatable ring. The circular motion of the ring traveler around the ring-frame bobbin causes the drawn associated roving thread to twist around the drawn associated spandex core, forming a core spun yarn.

A woven textile fabric includes a warp yarn and a weft yarn. The weft yarn is a core spun yarn having a spandex core, and the woven textile fabric is a sateen weave and/or a plain weave.

A mattress or mattress topper includes a cushioning element having an elastomeric material forming intersecting buckling walls that define hollow columns, and a knitted fabric disposed over the cushioning element and configured to move independently of the buckling walls. The elastomeric material includes an elastomeric polymer and a plasticizer. The knitted fabric includes a first layer of stretchable material; a second layer of stretchable material; and a layer of stretchable fill material between the first layer of stretchable material and the second layer of stretchable material. The first layer of stretchable material is knitted together with the second layer of stretchable material as a unitary sheet of fabric including the layer of stretchable fill material. A method of forming a mattress or mattress topper includes disposing a knitted fabric over a cushioning element comprising intersecting buckling walls and configuring the knitted fabric to move independently of the buckling walls.

Disclosed are a method, a device and/or a system of proliferating a thread count of a woven textile by simultaneous insertion within a single pick insertion event of a loom apparatus multiple adjacent parallel yarns drawn from a multi-pick yarn package. In one or more embodiments, multiple texturized polyester weft yarns of denier between 15 and 65 are wound on a single bobbin in a parallel adjacent fashion such that they may be fed into an air jet pick insertion apparatus and/or a rapier pick insertion apparatus of an air jet loom to weave a textile that has between 90 to 235 ends per inch cotton warp yarns and between 100 and 965 polyester weft yarns.

A method of producing a core spun yarn is disclosed. A oriented polyester yarn is drawn through a primary heater and exposed to a cooling plate. The oriented polyester yarn is drawn through a friction twisting unit. A spandex core is drawn from a spandex bobbin to become associated with the oriented polyester yarn. Both the spandex core and the oriented polyester yarn are drawn through an intermingling jet, which texturizes the oriented polyester yarn using a hot air punching technique. The oriented polyester yarn is twisted around the spandex core using the intermingling jet and/or the friction twisting unit. The oriented polyester yarn and the spandex core are drawn through a NFR roller and then heated to form the core spun yarn.

A yarn or thread may include a plurality of substantially aligned filaments, with at least ninety-five percent of a material of the filaments being a thermoplastic polymer material. Various woven textiles and knitted textiles may be formed from the yarn or thread. The woven textiles or knitted textiles may be thermal bonded to other elements to form seams. A strand that is at least partially formed from a thermoplastic polymer material may extend through the seam, and the strand may be thermal bonded at the seam. The woven textiles or knitted textiles may be shaped or molded, incorporated into products, and recycled to form other products.

Percale weave sheeting has warp yarn and weft yarn. The percale weave sheeting has two surfaces. Both surfaces exhibit color consistency. The warp yarn and the weft yarn are a cross weave of cotton and polyester.

An embodiment of the present disclosure is a woven fabric comprising a plurality of warp yarns. Each one the warp yarns is a staple spun yarn. The fabric includes a plurality of weft yarns interwoven with the plurality of warp yarns to define the woven fabric. Each one of the plurality of weft yarns is a high bulk textured continuous filament yarn. The woven fabric defies a first side and a second side that is opposed to the first side. The plurality of weft yarns are interwoven with the plurality of warp yarns such that the weft yarns define a substantial majority of the face of the woven fabric, thereby exposing high bulk textured continuous filament yarns along a substantial majority of the face.