ULTRASONIC PEEL AWAY TEXTILE GOODS

Abstract

A multi-layered article for bedding or clothing protection formed of a base layer and having a waterproof or water resistant side, together with a plurality of sheet layers, each sheet layer having a waterproof or water resistant side; and commonly welded together preferably with performations. The sheet layers are individually removable as needed.

Claims

1. A multi-layered protector article comprising: a generally rectangular unfolded base layer; and a generally rectangular upper portion including a plurality of removable layers overlaid on one another, said upper portion commonly adhered to and with said base layer by at least one weld, at least part of said at least one weld co-located in a line with a plurality of perforations where at least some of said weld is used to demarcate the perforations; wherein each of said plurality of removable layers is defined by said plurality of perforations along at least one side and each said removable layer is individually removable from said article at said perforations, said article is formed at least in part using a bioplastic, and said article is at least in part biodegradable.

2. The multi-layered article of claim 1, wherein said removable layer includes a waterproof membrane on at least one side.

3. The multi-layered article of claim 2, wherein the side opposing the side with said waterproof membrane is comprised of at least one of cotton, rayon, polyester, bamboo, lyocell, hemp, or flax.

4. The multi-layered article of claim 2, wherein said waterproof membrane is micro-porous or non-porous and has a thickness of at least 0.001 mm.

5. The multi-layer article of claim 2, wherein said waterproof membrane includes a laminated side.

6. The multi-layered article of claim 2, wherein the waterproof membrane comprises at least one of at least one of polyethylene, polyurethane, polyvinylchloride, polybutylene, latex, or silicone.

7. The multi-layered article of claim 2, wherein said generally rectangular base layer further includes a portion arranged to wrap around the side of a mattress and elasticized edging for fitting to said mattress with each said waterproof layer functioning as a mattress protector.

8. The multi-layered article of claim 1, wherein said at least one removable layer includes an unperforated tab.

9. The multi-layered article of claim 8, wherein each layer of said plurality of removable layers is removable through use of said perforations and tab.

10. The multi-layered article of claim 1 wherein said at least one weld is an ultrasonic weld.

11. The multi-layered article of claim 1, wherein said article is a clothing protector.

12. The multi-layered article of claim 1, wherein said article is a seat cover.

13. The multi-layered article of claim 1, wherein said article is formed, at least in part, of a non-woven material with a parallel or cross grain pattern with at least about 20 grams per square inch.

14. The multi-layer article of claim 1, wherein a second side of each removable layer faces away from said base layer, and is formed of at least of non-woven fabric.

15. The multi-layer article of claim 1, wherein said base layer includes an element for attaching to a person.

16. The multi-layer article of claim 1, wherein at least one said removable layer, includes a water resistant layer.

17. The multi-layer article of claim 1, wherein said perforations are arranged at least in part linearly in alignment with said at least one weld.

18. A method of manufacturing a layered bed sheetset, comprising the steps of: forming a bottom fitted sheet including elasticized edging having a waterproof or water resistant side; forming an upper sheetset comprising a plurality of sheet layers overlaid one over the next, each sheet layer having a waterproof side; and a comfort side; and ultrasonically welding said plurality of sheet layers to said bottom fitted sheet along at least one ultrasonic weld line in a welding process; wherein each said sheet layer includes at least one generally linear perforation, said perforation comprising a series of openings where said series extends generally linearly for a length at least approximately equal to the length of the bed for which the protector is intended.

19. The method of manufacturing of claim 18, wherein the waterproof side of each sheet layer is attached to its respective sheet layer by heating or gluing.

20. The method of manufacturing of claim 18, wherein said at least one ultrasonic weld line is coincident with said at least one generally linear perforation.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0022] FIG. 1 depicts a layered mattress protector according to the present invention;

[0023] FIG. 2 depicts a layered mattress protector according to the present invention;

[0024] FIG. 3 depicts a layered mattress protector according to the present invention;

[0025] FIG. 4 depicts a layered mattress protector according to the present invention;

[0026] FIG. 5 depicts a layered mattress protector according to the present invention;

[0027] FIG. 6 depicts a layered mattress protector according to the present invention;

[0028] FIG. 7 depicts a layered mattress protector according to the present invention;

[0029] FIG. 8 depicts a layered mattress protector according to the present invention;

[0030] FIG. 9 depicts a layered mattress protector according to the present invention;

[0031] FIG. 10 depicts a layered mattress protector according to the present invention.

[0032] FIG. 11 depicts a layered mattress protector according to the present invention.

[0033] FIG. 12 depicts a layered mattress protector according to the present invention.

DETAILED DESCRIPTION OF THE PRESENT INVENTION

[0034] The present invention is directed to a multi-layered sheetset product with a plurality of removable, peelable layers sized for use as bedding with beds sized such as but not limited to porta crib, crib, changing table, toddler bed, twin-size bed, twinXL-size bed, full-size bed, queen-size bed, king-size bed, or California King-sized bed. Alternatively, the multi-layer product of the present invention is usable as bedding, an apron, a bib, etc. In another embodiment, the present invention is directed to a multi-layered mattress protector with removable, peelable or removable layers in the same size. In another embodiment, the present invention is directed to a multi-layered car seat cover with removable layers. In another embodiment, the present invention is directed to a multi-layered baby bibs with removable, peelable layers. In another embodiment, the present invention is directed to a multi-layered cooking apron with removable, peelable layers. More generally, the present invention is directed to textile goods where the textile would have a plurality of layers, each layer being separately (or collectively) removable from the textile, such as for reasons of a layer of the textile having become dirty or soiled.

[0035] In general, the present invention is directed to a multi-layer product, where each layer has a top side comprising a material, materials, and/or a surface pleasing to the intended usee.g., cotton or flannel for use as a bed sheetand an opposing side comprising a material, materials, and/or a surface conformant to other possible usese.g., waterproof materials for protecting a mattress. In addition, each layer in the multi-layer product is similarly constructed and the exposed or outer layer can easily be removed, for example, once its useful life has completed.

[0036] In general, the multi-layer product of the present invention is comprised of a plurality of layers, including a base layer and a plurality of upper layers, in which each of the plurality of upper layers may be removable one at a time.

[0037] In general, the base layer is a part of a larger assembly. For example, the base layer of an apron may include elements for attaching to a person. In another example, the base layer of a sheet or mattress cover may include the fitting sections for surrounding and attaching to a mattress as a fitted sheet would. In another example involving a sheet, the base layer may include or be attached to bed decorative borders.

[0038] In general, the product of the present invention includes a plurality of upper layers which are collectively attached to the base layer in some way such that each of said upper layers can be individually removed for discarding. Each layer can be attached using breakaway stitching or include perforations for tearing, or some combination. Typically, the aforementioned stitching or perforations might be included on less than all edges.

[0039] In order to remove each layer, the present textile includes one or more seams at which the layers are collectively attached. The seam could include stitching, stitching with holes, or compressed areas, or any combination, any of which might be usable for separating one layer from the others.

[0040] In an additional embodiment of the present invention, ultrasonic cutting and welding is used for formulating seams and the seams themselves comprise ultrasonic welds. Welding is often alternatively referred to as heat-sealing wherein the seam is formed by use of heat and/or sound waves to make fused indentations and/or holes, weld portions of a plurality of sheets together, and/or create easily tear-away boundaries. These seams are usable for peeling away individual layers of the sheets of the present invention. In one embodiment, the created seam can be a point for tearing. This ultrasonic or heat process can also be used for inserting holes in the seams, such as sized and spaced to facilitate tearing, thereby facilitating layer separation. In addition, the process of ultrasonic welding and cutting is a single step process resulting in both punching and sealing. The benefits to such welding include that the resultant textile does not fray, it shows no burns or other undesirable anomalies, and requires less time and energy required for manufacture (thereby reducing cost). The textile of the present invention in at least this embodiment does not have a selvage (no fray able edges) and thereby will not fray. By using ultrasonic welding, a perforated seam may be created and incorporated into the textile to form a tearable and/or perforated seam.

[0041] The use of ultrasonically forming the seam and/or holes also results in reduced use of goods for manufacture (like threads), no need for sewing, and no emission of toxic fumes.

[0042] In yet an additional embodiment, the present invention incorporates, in part or in whole, biodegradable materials and/or bioplastics. Bioplastics are plastic materials produced from renewable biomass sources, such as vegetable fats and oils, or other goods in natural form such as but not limited to corn starch, straw, woodchips, sawdust, recycled food waste, etc. Bioplastic can be made from agricultural by-products and also from used plastic bottles and other containers using microorganisms. Examples of bioplastics, any of which could be a part of the present invention, include: [0043] Polylactic acid (PLA) [0044] Polyamide 11. [0045] Polyhydroxyalkanoate. [0046] Bio-derived polyethylene. [0047] Starch-based plastics. [0048] Cellulose-based plastics. [0049] Protein-based plastics. [0050] Lipid-derived polymers.

[0051] Importantly, in the present invention, the product may be made entirely of one or more bioplastics or only the seam area may be made of the bioplastic material(s).

[0052] In any of the aforementioned embodiments, the product may alternatively or additionally be formed of non-woven (spunlace) fabric that preferably has a parallel or cross grain pattern with a minimum of 20 grams per square meter. In another embodiment, the product is formed of woven fabric. In another embodiment, the product can be formed of a combination of non-woven and woven fabrics. The material used can be comprised of one of or a blend of cotton, bamboo, polyester, rayon, tensel, hemp, flax or any other fiber that can be made into a non-woven or woven material.

[0053] Preferably the fabric of the present invention has a waterproof membrane, preferably laminated, with a minimum thickness of 0.001 mm that is either breathable (micro-porous) or non-breathable, on at least a portion of one side. The laminated membrane is on the bottom side of the fabric. In the preferred embodiment, the membrane is affixed to the fabric by either heat or a gluing process, and is made from at least one of polyethylene, polyurethane, poly vinyl chloride, polybutylene, latex, silicone or any other waterproofed material, either alone by itself or in combination with any other named or inferred material, such as but not limited to those described herein and is assembled into a multi-layered finished product. In a sheetset, the waterproof layer would be the layer facing the mattress and is referred to herein as the under side. The laminated member of the present invention might extend to the entirety of a sheet or might just extend to a portion of the sheet, depending upon need, cost, and manufacturability. For example, a sheet in the plurality of sheets might have edge stitching for connecting to a base sheet, and the laminate member could potentially only extend to the stitching.

[0054] The other side, or over side, is formed of materials appropriate to use, such as cotton or flannel for a bedsheet.

[0055] Particularly when used as bedding, the article of the present invention includes sheets with two sides. The side closest to the mattress is intended to provide for a water barrier so as to protect the mattress from spills, soiling, and the like. That same side also has the added feature of comparatively high friction in that it is intended not to slip or shift relative to the mattress. The other side, or the side away from the mattress and the side which will come in contact with a person, is intended to be formed of a material to provide comfort to the person. Non-limiting examples are cotton and cotton flannel. The two sides of each sheet are bonded together to form a single sheet, where the bonding is preferably through heat or gluing. However, the bonding is intended not to adversely impact the benefits described above.

[0056] In the preferred embodiment, the product is multi-layer, and each layer is individually peelable. The layers are combined together either by stitching, such as by using a hook and loop system, such as Velcro, a zipper, and/or a removable adhesive, either alone or in combination. The layers can be married to a bed skirt, or to a solid fabric, that can be made of any material, that can have elastic attached to allow for a form fit or an edge made of any material to complete the apron or baby bib.

[0057] With regard to the peel away attributes of the present invention, the goal is for a user, with limited effort, to separate the exposed sheet from the remaining sheets. To accomplish this goal, each successive sheet is attached to the remainder of the sheetset in such a way so that the sheet remains functional (if, for example, used as a sheet, it should be comfortable to sleep on), yet is easily removable.

[0058] The attachment may be by means of adherence (such as by gluing or heating) or stitching, as examples. Ultrasonic welding and cutting may be used. Known alternatives may alternatively be used. In an alternate embodiment, the attachment may be by stitching. Stitching may be accomplished on a sheet by sheer basis or collectively with one stitching.

[0059] In at least some embodiments, the stitching may be used in combination with perforations. For a user to remove each sheet the sheet will tear off at the perforation. In at least some embodiments, one or more tabs can be included on each sheer to facilitate removal.

[0060] In one embodiment, ultrasonic welding may be used in combination with perforations. For a user to remove each sheet the sheet will tear off at the perforation. In at least some embodiments, one or more tabs can be included on each sheet to facilitate removal.

[0061] In an alternative embodiment, the stitching and the material together are of the form of breakaway stitching, wherein a layer can be removed by a user when pulling at the location of the stitching, and the layer is torn away from the remainder of the article.

[0062] In the preferred embodiment with perforations, the perforations will extend on two opposing sides only. That is, for a bedsheet, the perforations would typically be on the two long sides of the bed. The perforations could be located along a line denoting the edge between the top and the side of the mattress, it could be along the line denoting the edge between the bottom and the side of the mattress, or it could be elsewhere. Wherever it might be, a remnant might be left behind. For an apron, the perforation might only be on one side. Once torn away, the product of the present invention is discardable.

[0063] In at least some embodiments, the removable layers are sized identically to one another and to the base layer. In other embodiments, the size of the removable layers may vary (becoming either smaller or larger as they become more proximal to the base layer). In some embodiments, the removable layers are generally sized for only the top of the mattress, whereas the base layer is sized comparably to a fitted sheet.

[0064] The figures included herein are directed to only some of the embodiments described herein.

[0065] The following detailed description is of the best currently contemplated modes of carrying out the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims. When dimensions are included, the reader should view these as exemplary only and not limiting in any way.

[0066] With reference to FIGS. 1-12, the present invention provides a layered mattress protector and sheet (10). It is noted that two embodiments are shown. FIGS. 1-5 depict one embodiment having a perforation that runs substantially parallel to the top side (34), bottom side (36), right side (40) and left side (38) and includes a tab (50). FIGS. 6-8 depict a preferred embodiment, in which there are only two perforations, that are perforation seams (80), that are substantially parallel to the right side and left side in each of at least three fitted sheet layers. They are also slightly inside the right side and left side of each of the at least three fitted sheet layers, which is to say they are located closer to the center point of each of the at least three fitted sheet layers. The layered mattress protector and sheet may have a bottom fitted portion (12, 112); at least three fitted sheet layers (e.g. 20, 22, 24, 26, 28, 30, 32, 120, 122, 124, 126, 128, 130 and 132). While there may be any number of fitted sheet layers, according to one preferred embodiment there are seven layers. Each fitted sheet layer has a top side (34, 134), bottom side (36, 136), right side (40, 140) and left side (38, 138) and an upper portion (42, 142) and lower portion (44, 144). Note that the numbers for the different sides are shown for one layer of the many layers of the fitted sheet layers. Each layer would have the same sides. There may be a waterproof polyethylene coating on the lower portion (44, 144) of each of the at least three fitted sheet layers. It should be understood that a waterproof layer would be equivalent to a waterproof coating and the terms are interchangeable. The upper portion of each fitted sheet layer may be rayon (also referred to as spunlace rayon). The at least three fitted sheet layers are stitched along the right side (40, 140) and left side (38, 138) to the bottom fitted portion (12, 112) and the top side (34, 134) and bottom side (36, 136) are unstitched. Each of the at least three fitted sheet layers has at least one perforation (46, 146). According to one embodiment, depicted in FIGS. 1-5, there is a single perforation that runs substantially parallel to the top side (34), bottom side (36), right side (40) and left side (38) and includes a tab cutout portion (50). The term perforation may be a series of small holes that allows for the fitted sheet layers to be removably attached, it may also be a perforation seam, that is a seam that is stitched creating holes, or perforations, yet having the added stability of a seam. The perforation (46, 146 also referred to as a perforation seam) creates a portion of the fitted sheet layer that is smaller than the entire fitted sheet layer that may be easily removed to reveal another, new fitted sheet layer below it. There is also a waterproof coating on the lower portion (44, 144) of each of the at least three fitted sheet layers. The at least three fitted sheet layers are stitched along the right side (40, 140) and left side (38, 138) to the bottom fitted portion (12, 112) and the top side (34, 134) and bottom side (36, 136) are unstitched. Each of the at least three fitted sheet layers has at least one perforation (46, 146) that is at least substantially parallel to the right side and left side in each of at least three fitted sheet layers.

[0067] The at least three fitted sheet layers may be stitched along the right side (40, 140) and left side (38, 138) to the bottom fitted portion (12, 112) along a portion of the right side (40, 140) and a portion of the left side (38, 138) to leave an unstitched portion (48) along a portion of each end of the right side and the left side. The unstitched portion (48) along a portion of each end of the right side and the left side may be between one and three inches, preferably one and a half inches. This allows for the easy removal of each layers of the at least three fitted sheet layers. It is not required that the unstitched portion (48) be along both sides, it may be along either a portion of the right side (40, 140) or a portion of the left side (38, 138). It should be towards one end of the right (right side (40, 140) or the left side (38, 138). The term end is intended to denote the area close to the top side (34, 134) or the bottom side (36, 136). The unstitched portion (48) along a portion of at least one end of the right side and the left side may be between one and three inches, preferably one and a half inches.

[0068] The upper portion (42) of each fitted sheet layer may any fabric that is desirable to the user, such as polyester and/or rayon fiber. The fitted sheet layers may be all the same size. According to an alternate embodiment, each of the at least three fitted sheet layers is slightly larger than the layer that is below it. As shown in FIG. 3, fitter sheet layer (20) is the biggest and has a perforation at 3829, fitted sheet layer (22) is slightly smaller and has a perforation at 38 6/829 6/8, fitted sheet layer (24) is slightly smaller and has a perforation at 3829, fitted sheet layer (26) is slightly smaller and has a perforation at 38 4/829 4/8, fitted sheet layer (28) is slightly smaller and has a perforation at 3829, fitted sheet layer (30) is slightly smaller and has a perforation at 38 2/829 2/8 and fitted sheet layer (32) is slightly smaller and has a perforation at 3829. As can be seen each perforated portion of the at least three fitted sheet layers is slightly larger than the layer that is below it.

[0069] Each perforated portion, according to an alternate embodiment, may have a tab cutout portion (50). The tab cutout portion (50) may be between a portion of the perforated portion (46) and at least one of the top side (34), bottom side (36), right side (40) and left side (38) of the at least three fitted sheet layers. According to one embodiment, the tab cutout portion (50) is away from the top side (34). This is to prevent inadvertent removal of a layer and any possible discomfort to the user. The top side (34) may be sewn with a rounded stich that edges the top side to provide an edged top side. The top side (34) may also be stitched to provide a stitched rolled hem top side (54). There may also be a printed item (56) on the upper portion of the at least three fitted sheet layers. The printed item (56) may be a school logo, or it may be, by way of example, say October as a reminder to pull off the layer at the end of October. Of course, it could say October 1, the next layer October 15, the next layer November 1, etc. In this way, the user is reminded of when to change their sheets.

[0070] Another aspect of the present invention provides a method of method of manufacturing a layered mattress protector and sheet, comprising: providing a bottom fitted portion (12, 112); providing at least three fitted sheet layers (e.g. 20, 22, 24, 26, 28, 30, 32, 120, 122, 124, 126, 128, 130 and 132), each fitted sheet layer having a top side (34, 134), bottom side (36, 136), right side (40, 140) and left side (38, 138) and an upper portion (42, 142) and lower portion (44, 144), wherein the lower portion (44, 144) of each of the at least three fitted sheet layers has a waterproof coating; providing at least one perforation (46, 146) that is at least substantially parallel to the right side and left side in each of at least three fitted sheet layers; stitching the at least three fitted sheet layers along the right side and left side to the bottom fitted portion and leaving the top side and bottom side unstitched. The step of stitching the at least three fitted sheet layers along the right side (40, 140) and left side (38, 138) to the bottom fitted portion (12, 112) and leaving the top side (34, 134) and bottom side (36, 136) unstitched may be further comprising the step of: stitching along the right side and left side to the bottom fitted portion to leave an unstitched portion (48) along at least one end of the right side and the left side. The unstitched portion (48) along at least one end of the right side and the left side is between one and three inches, preferably one and a half inches. Each of the at least one perforations (46, 146) of the at least three fitted sheet layers may be slightly larger than the layer that is below it. There may be the step of providing a tab cutout portion (50). The tab cutout portion (50) may be along at least one of the top side, bottom side, right side and left side of the at least three fitted sheet layers. There may be the step of sewing the top side with a rounded stich that edges the top side to provide an edged top side. There may be the step of stitching the top side to provide a stitched rolled hem top side. There may also be the step of printing a printed item (56) on the upper portion of each of the at least three fitted sheet layers.

[0071] FIGS. 10, 11 and 12 depict a layered mattress protector according to the present invention.

[0072] FIG. 11 depicts a preferred embodiment of the present invention. A layered mattress protector and sheet is provided with a bottom fitted portion (1110); at least three fitted sheet layers (1112), each fitted sheet layer having a top side (1100), bottom side (1102), right side (1108) and left side (1106) and an upper portion (1112) and lower portion (not seen in FIG. 11, would be the portion opposing the upper portion (1112) on the underneath of the three fitted sheet layers). Also note that the at least three fitted sheet layers are layered, so FIG. 11 only depicts one of the layers, but there are at least three fitted sheet layers, as depicted in other figures. There is a waterproof coating on the lower portion of each of the at least three fitted sheet layers (1112). The at least three fitted sheet layers (1112) are stitched along the right side (1106) and left side (1108) to the bottom fitted portion (1110) the stitch creating at least one perforation seam and the top side (1100) and bottom side (1102) are unstitched to the bottom fitted portion (1110) leaving open ends; and the top side (1100) is an edged top side (1104). FIG. 12 depicts a picture of the edged top side of each of the at least three fitted sheet layers (1112) according to the present invention and the top side being unstitched. It should be understood that the foregoing relates to preferred embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims.