Fabric System

Abstract

Bedding material including a first fabric section manufactured from performance fabric and having a first and second side; and, a second fabric section attached to the first side of the first fabric section. Additionally, a third fabric section can be attached to the second side of the first fabric section. The first fabric section can be attached to the second fabric section through a flatlock stitch. The first fabric section can include a first zone and a second zone wherein the first zone contains different performance properties from the second zone and the first zone can have thermal or moisture wicking properties.

Claims

1. A bed covering at least 90 inches wide comprising a circularly knit fabric area where a majority of an individual body is capable of resting when the bed covering is on a bed, the circularly knit fabric area formed from a fabric knit at 17 gauges or higher with at least one elastic synthetic fiber, such that the fabric has an elasticity which results in a tendency of the fabric to sag that would interfere with a finishing process if the fabric were circularly knit at greater than a 72.5 inch circumference.

2. The bed covering of claim 1 comprising at least two joined discrete portions of fabric.

3. The bed covering of claim 15 comprising one portion of circularly knit fabric and one or more portions of fabric other than circularly knit fabric.

4. The bed covering of claim 14 in which the fabric comprises polyurethanepolyurea copolymer fiber.

5. The bed covering of claim 17 in which the fabric comprises polyurethanepolyurea copolymer fiber in a proportion such that, if the fabric had been circularly knit at a high gauge, the fabric could have been knit at no more than a 72.5 inch circumference without losing integrity of the polyurethanepolyurea copolymer fiber.

6. The bed covering of claim 14 having dimensions of approximately 102 inches in length and approximately 91 inches in width when the bed covering is not stretched.

7. The bed covering of claim 14 in which the circularly knit fabric area has a width of a full size bed.

8. The bed covering of claim 14 in which the circularly knit fabric area has a width of a queen size bed.

9. A bed covering at least 90 inches wide comprising a circularly knit fabric area where the majority of an individual body is capable of resting when the bed covering is on a bed, the circularly knit fabric area comprising a fabric including polyurethanepolyurea copolymer fiber and having been circularly knit at 17 gauges or higher, the fabric comprising the polyurethanepolyurea copolymer fiber in a proportion such that, if circularly knit at a high gauge, the circularly knit fabric area could be knit at no more than a 72.5 inch circumference without losing integrity of the polyurethanepolyurea copolymer fiber.

10. The bed covering of claim 22 in which the bed covering comprises at least two joined discrete portions of the circularly knit fabric.

11. The bed covering of claim 22 comprising one portion of circularly knit fabric and one or more portions of fabric other than circularly knit fabric.

12. The bed covering of claim 22 in which the circularly knit fabric area comprises polyurethanepolyurea copolymer fiber in a proportion such that the circularly knit fabric has higher breathability than a cotton fabric.

13. The bed covering of claim 22 in which the polyurethanepolyurea copolymer fiber is included in the fabric of the circularly knit fabric area in a proportion such that the circularly knit fabric area has higher heat transfer than a cotton fabric.

14. The bed covering of claim 22 in which the fabric of the circularly knit fabric area comprises the polyurethanepolyurea copolymer fiber in a proportion such that the circularly knit fabric area has higher moisture wicking characteristics than a cotton fabric.

15. The bed covering of claim 22 in which the fabric area has a width of a full size bed.

16. The bed covering of claim 22 in which the fabric area has a width of a queen size bed.

17. A bed covering comprising: a finished fabric having a width of at least 90 inches and comprising: a first fabric portion where a majority of an individual body is capable of resting when the bed covering is on a bed; and two or more second fabric portions attached to the first fabric portion, wherein: the first fabric portion forms a majority of the finished fabric; the first fabric portion and at least two of the second fabric portions in combination extend across the width of the finished fabric; and the first fabric portion is formed from a circularly knit fabric knit at 17 gauges or higher with at least one elastic synthetic fiber, such that the circularly knit fabric has an elasticity which results in a tendency of the fabric to sag that would interfere with a finishing process if the circularly knit fabric were circularly knit at greater than a 72.5 inch circumference.

18. The bed covering of claim 30, wherein the circularly knit fabric comprises polyurethanepolyurea copolymer fiber.

19. The bed covering of claim 30, a proportion of the polyurethanepolyurea copolymer fiber in the circularly knit fabric is such that if the circularly knit fabric had been circularly knit at a high gauge, the circularly knit fabric could have been knit at no more than a 72.5 inch circumference without losing integrity of the polyurethanepolyurea copolymer fiber.

20. The bed covering of claim 30, wherein the first fabric portion has a width of one of a full size bed or a queen size bed.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0035] FIG. 1 illustrates a preferred embodiment of the present invention.

[0036] FIG. 2 illustrates another preferred embodiment of the present invention.

[0037] FIG. 3A illustrates a further preferred embodiment of the present invention.

[0038] FIG. 3B illustrates pull ties useful with a preferred embodiment of the present invention.

[0039] FIG. 3C illustrates a cinched pull tie of FIG. 3B.

[0040] FIG. 3D-3E illustrate stitching embodiments useful for securing portions of the present invention together.

[0041] FIG. 4 illustrates another preferred embodiment of the present invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0042] Although preferred embodiments of the invention are explained in detail, it is to be understood that other embodiments are contemplated. Accordingly, it is not intended that the invention is limited in its scope to the details of construction and arrangement of components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or carried out in various ways. Also, in describing the preferred embodiments, specific terminology will be resorted to for the sake of clarity.

[0043] It must also be noted that, as used in the specification and the appended claims, the singular forms a, an and the include plural referents unless the context clearly dictates otherwise. For example, reference to a sheet or portion is intended also to include the manufacturing of a plurality of sheets or portions. References to a sheet containing a constituent is intended to include other constituents in addition to the one named.

[0044] Also, in describing the preferred embodiments, terminology will be resorted to for the sake of clarity. It is intended that each term contemplates its broadest meaning as understood by those skilled in the art and includes all technical equivalents which operate in a similar manner to accomplish a similar purpose.

[0045] Ranges may be expressed herein as from about or approximately one particular value and/or to about or approximately another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value.

[0046] By comprising or containing or including is meant that at least the named compound, element, particle, or method step is present in the composition or article or method, but does not exclude the presence of other compounds, materials, particles, method steps, even if the other such compounds, material, particles, method steps have the same function as what is named.

[0047] It is also to be understood that the mention of one or more method steps does not preclude the presence of additional method steps or intervening method steps between those steps expressly identified. Similarly, it is also to be understood that the mention of one or more components in a fabric or system does not preclude the presence of additional components or intervening components between those components expressly identified.

[0048] Referring now in detail to the drawing figures, wherein like reference numerals represent like parts throughout the several views, the present invention of FIGS. 1 and 4 provides a sheet 10 shown having dimensions of 102 inches in length and 91 inches in width. The material is manufactured from performance fabric, which can include, for example, varying amounts of one or more of Lycra, Coolmax, Thermax and Thermastat. In a preferred embodiment, the fabric is treated so that the fabric has antimicrobial properties. By using circular-knit performance fabric, the fabric is able to provide elasticity in all four directions. This property allows for the sheet to fit extraordinary mattress, cushion and bedding shapes, as well as providing better fits for traditional rectangular sheets. By using performance fabrics, the sheet has elastic properties that allow stretching in the directions shown as 30. In addition, by using circular-knit performance fabric, the resulting bedding retains an exceptionally fine tactile quality critical for providing maximum levels of enhanced comfort.

[0049] An alternative to circular knitting is non-circular knittingfor example, warp knitting. This method can achieve widths greater than circular knitting. Industrial warp knit machines, for example, can produce tricote warp knit fabrics up to 130-140 inches in width. Circular knitting, however, is less expensive, as it requires less set-up time. Circular knitting also provides greater multidirectional stretch.

[0050] In order to provide a sheet that exceeds the maximum dimensions of fabric that can be produced by available circular knitting machines, flat lock stitching 12 is used to join a plurality of portions resulting in a sheet that is 91 inches wide (as shown). In an exemplary embodiment, piping 11 can be included in close proximity to the stitching. The stitching can be the same color as the fabric of the sheet portions, or different color(s). The piping can be inch straight piping without a cord or other filler. In one preferred embodiment, the stitching is 16 stitches per inch. Piping 11 can be included at one end of the sheet and can be the same or a different color as the sheet fabric.

[0051] For a fitted sheet, the sheet can include an elastic portion surrounding the edge of the fitted sheet to better keep the fitted sheet in place when placed on a mattress or other sleeping surface. A cord can be sewn into the edge of the fitted sheet and cinched around the mattress or other sleeping surface to better hold the fitted sheet in place.

[0052] Referring to FIG. 2, a sheet is shown having dimensions of 91 inches wide and 102 inches in length. In this embodiment, stitching 14 is shown 34 inches from an interior edge 18 of a main portion 16 and another stitch 14 at edge 20 of the sewn-on portion. Flat lock stitching can be used for the stitching. Piping can be applied at or in proximity to the stitching.

[0053] Referring to FIGS. 3A-E, a non-rectangular shaped sheet is shown in FIG. 3A. In this exemplary embodiment, elastic can be included around the edge of the fitted sheet to better maintain the fitted sheet in position when placed on a sleeping surface. In one embodiment, pull ties 24 (FIG. 3B) can be installed at various locations around the edge of the fitted sheet in order to assist in maintaining the fitted sheet secured to the sleeping surface. The pull tie can be cinched to increase tension around the edge of the fitted sheet as shown by 26 (FIG. 3C).

[0054] Stitching used for securing the portions of the sheet together can include that shown in FIGS. 3D-3E, for example as 28a. In another embodiment, the stitching used for securing the portion of fabric together is shown as 28b.

[0055] Referring to FIG. 4, yet another preferred embodiment of the invention is shown. In this embodiment, the sheet can be assembled through stitching of differing fabrics for generating performance zones in the sheet. For example, zone 32 can have higher wicking properties than the other zones since this area is where the majority of the individual body rests. Areas 34a through 34d can have higher spandex or other elastic fabric properties so that the fit around a sleeping surface is improved. Area 36 may have thermal properties such as increased cooling since this area is generally where the individual's head lies. In an exemplary embodiment, the pillow covers of pillows used by the individual also have differing properties from the remainder of the sheet, e.g., thermal properties.

[0056] The present invention encompasses the construction of bedding materials that have superior performance properties while allowing for manufacture by machinery presently available and in use. More specifically, the invention is related to a new method for fabricating a covering and or sheets in bedding. When using the circular knitting machine, the high gauge performance fabrics can only be made to a maximum size of 72.5 inches without losing the integrity of the spandex in the fabric. Yet, normal sheet panels are 10291 inches. This presents problems when manufacturing sheets from performance fabrics.

[0057] Additionally, special stitching techniques must be used given the thread density of the fabric. Using this special stitching, panels are sewn together to produce bedding or a sheet that is the proper size for standard bed sheets. Because discrete portions/panels are used in the manufacture of the present fabrics, panels can be selected that provide different properties for different areas of the bedding (FIG. 4). Stitching or seams on the sheet can also allow for the ease of making the bed. Because the bedding is made from performance fabric with spandex, it stretches to permit multiple and custom sizing for applications in cribs, recreational vehicles and boats.

[0058] Circular knitting machines used for high gauge performance bedding fabrics are called high-gauge circular knitting machines, because of dense knitting with thin yarn. High gauge generally denotes 17 gauges or more. Seventeen gauges indicate that 17 or more cylinder needles are contained in one inch. Circular knitting machines of less than 17 gauges are referred to as low-gauge circular knitting machines. The low-gauge circular knitting machines are often used to knit outerwear.

[0059] Yarn count indicates the linear density (yarn diameter or fineness) to which that particular yarn has been spun. The choice of yarn count is restricted by the type of knitting machine employed and the knitting construction. The yarn count, in turn, influences the cost, weight, opacity, hand and drape of the resulting knitted structure. In general, staple spun yarns tend to be comparatively more expensive the finer their count, because finer fibers and a more exacting spinning process are necessary in order to prevent the yarn from showing an irregular appearance.

[0060] A top width in the 90-inch range is currently possible using a circular knit fabric formed on a 36-38-inch diameter machine, although higher levels of spandex in the performance fabric tend to pull the width in. In just one example, on a 30-inch diameter machine, the spandex can reduce an otherwise 94-inch circumference fabric tube to one with a 60-65 inch finished width.

[0061] A major limitation in finished width is not strictly a knitting concern but also concerns finishing. With performance fabric, it tends to sag in the middleincreasingly so with greater widthsmaking finishing difficult to impossible above a certain threshold. A possible 90-inch finished width is contingent upon having a good finishing set-up capable of handling the present performance fabric. This potential for difficulties would only become compounded at the larger widths required for bed sheets.

[0062] In a preferred process, the present fabric undergoes a heat setting finishing process. Applying a moisture-wicking finish to another fabriclike cottonthat can be produced at larger widths appears unlikely to match the moisture-control properties of the present fabric, as polyester itself is naturally moisture-resistant and there are physical actions (e.g. capillary action) at play. Further, the use of cotton comes at the expense of breathability and heat-transfer capabilities (as confirmed by laboratory testing) and stretchability.

[0063] Numerous characteristics and advantages have been set forth in the foregoing description, together with details of structure and function. While the invention has been disclosed in several forms, it will be apparent to those skilled in the art that many modifications, additions, and deletions, especially in matters of shape, size, and arrangement of parts, can be made therein without departing from the spirit and scope of the invention and its equivalents as set forth in the following claims. Therefore, other modifications or embodiments as may be suggested by the teachings herein are particularly reserved as they fall within the breadth and scope of the claims here appended.