Percale Bedding System

Abstract

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.

Claims

1. Fabric fabricated of percale weave sheeting, the percale weave sheeting having two surfaces wherein both surfaces-exhibit color consistency, the percale weave sheeting having warp yarn and weft yarn, the warp yarn and the weft yarn being a cross weave of cotton and polyester.

2. The fabric as set forth in claim 1 wherein the percale weave sheeting is formed as a pillowcase.

3. The fabric as set forth in claim 1 wherein the percale weave sheeting is formed as a top sheet.

4. The fabric as set forth in claim 1 wherein the percale weave sheeting is formed as a fitted sheet.

5. The fabric as set forth in claim 1 wherein the percale weave sheeting is formed as pillowcases, a top sheet, and a fitted sheet.

6. The fabric as set forth in claim 1 wherein the warp yarn is cotton, 10 D D to 240 D denier and 30 s to 60 s thread count.

7. The fabric as set forth in claim 6 wherein the cotton is chief value cotton with a minimum of 51 percent cotton and 49 percent chosen from polyester/filament yarn and polyester spun yarn and cotton spun yarn.

8. The fabric as set forth in claim 1 wherein the weft yarn is polyester filament, low intermingle, 10 D D to 240 D denier and 14 filament to 36 filament thread count.

9. The fabric as set forth in claim 1 wherein the weft yarn is polyester filament, low intermingle, 10 D D to 240 D denier and 36 filament to 72 filament thread count.

10. The fabric as set forth in claim 1 wherein the weft yarn is polyester filament, low intermingle, 10 D D to 240 D denier and 72 filament to 108 filament thread count.

11. The fabric as set forth in claim 1 wherein the warp yarn is cotton filament, with a yarn count of 30 to 60 s, and 15 D to 240 D denier, and 14 to 216 filament, and wherein the weft yarn is polyester filament, low intermingled, 10 D D to 240 D denier and 14 to 216 filament thereby providing improved crispness.

12. The fabric as set forth in claim 1 wherein the cross weave is 1/1, 1 over and 1 under, whereby both surfaces comprise a proportion of cotton and a proportion of polyester, the proportion of cotton being greater than the proportion of polyester.

13. The fabric as set forth in claim 1 wherein the cross weave is , 1 over and 2 under.

14. The fabric as set forth in claim 1 wherein the cross weave is , 1 over and 4 under.

15. The fabric as set forth in claim 1 wherein with the sheeting has a high thread count of from 130 threads per inch to 00 threads per inch.

16. The fabric as set forth in claim 1 wherein with the sheeting has a high thread count of from 300 threads per inch to 600 threads per inch.

17. The fabric as set forth in claim 1 wherein with the sheeting has a high thread count of from 600 threads per inch to 800 threads per inch.

18. The fabric as set forth in claim 1 wherein with the sheeting has a high thread count of from 800 to 2000 threads per inch thereby exhibiting low pilling.

19. The fabric as set forth in claim 1 wherein the sheeting has a weight range of 80 to 250 grams per square meter thereby exhibiting high tensile strength.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:

[0021] FIG. 1 is a perspective illustration of a percale bedding system fabricated in accordance with the principles of the present invention.

[0022] FIG. 2 is a front elevational view of the top sheet and pillow cases of FIG. 1.

[0023] FIG. 3 is front elevational view of the fitted sheet of FIG. 1.

[0024] FIG. 4 is an enlarged front elevational view of the fabric of the bedding of the prior Figures.

[0025] FIG. 5 is a graph charting 15 denier to 240 denier polyester filament yarn against 140 thread count to 1200 thread count threads per inch of cotton rich grid.

[0026] FIG. 6 is a graph charting 15 denier to 240 denier polyester filament yarn against 140 thread count to 1200 thread count threads per inch and measuring tensile strength.

[0027] FIG. 7 is a graph charting 15 denier to 240 denier polyester filament yarn against 140 thread count to 1200 thread count threads per inch and measuring fabric increased durability grid.

[0028] The same reference numerals refer to the same parts throughout the various Figures.

DESCRIPTION OF THE PREFERRED EMBODIMENT

[0029] With reference now to the drawings, and in particular to FIG. 1 thereof, the preferred embodiment of the new and improved percale bedding system embodying the principles and concepts of the present invention and generally designated by the reference numeral 10 will be described.

[0030] The present invention, the percale bedding system 10 is comprised of a plurality of components. Such components in their broadest context include percale weave sheeting having warp yarn and weft yarn, the warp yarn and the weft yarn being a cross weave of cotton and polyester.

[0031] In the preferred embodiment, bedding 10 is characterized by anti-wrinkle capabilities, increased softness and increased durability/long life, and decreased cost. The bedding is fabricated of percale weave sheeting. The percale weave sheeting has two surfaces wherein both surfaces exhibit color consistency. The bedding includes one, two, or four pillow cases 12, a top sheet 14, and a fitted sheet 16.

[0032] The percale weave sheeting has cotton warp yarn 18 with a denier of 10 D to 240 D with 14 to 216 filament thread count. The cotton warp yarn has a thread count of 30 s to 60 s. The cotton warp yarn is a rich chief value cotton, CVC, with a 51 percent minimum of cotton and a 49 percent maximum of polyester/filament yarn, or polyester spun yarn, or polyester cotton spun yarn.

[0033] The percale weave sheeting has polyester weft yarn 20 with a denier of 10 D to 240 D. The polyester weft yarn is polyester filament, low intermingle. The polyester weft yarn is 14 filament to 216 filament thread count thereby providing improved crispness.

[0034] The percale weave sheeting has 130 to 2000 threads per square inch. The percale weave sheeting has a weight of 80 to 250 grams per square inch thereby exhibiting high tensile strength.

[0035] The cotton warp yarn and the polyester weft yarn in each surface are in across weave, 1/1, 1 over 1 and under. The warp and weft, which are preferably cotton and polyester, may be interchanged to polyester warp and cotton weft whereby both surfaces comprise a proportion of cotton and a proportion of polyester, the proportion of cotton being greater than the proportion of polyester.

[0036] In alternate embodiments, the fabric is formed as a pillowcase, a top sheet, or a fitted sheet. In another alternate embodiment, the bedding includes pillowcases, a top sheet, and a fitted sheet.

[0037] In a further alternate embodiment, the cross weave is 1/1, 1 over and 1 under. In another embodiment, the cross weave is 1 over and 2 under. In still another embodiment, the cross weave is , 1 over and 4 under.

[0038] The present invention is percale sheeting manufactured into fine products including luxury percale bed sheets, fitted sheets and pillow cases. Such products are characterized by a percale weave construction 1/1, 1 up 1 down, of a high thread count of at least about 130 threads per square inch to 2000 threads per square inch thereby exhibiting low pilling. Prior art percale sheets were either from 100 percent cotton or cotton with polyester filament yarn/polyester or spun yarn/polyester or cotton spun yarn. The sheeting of the present invention is chief value cotton, CVC, that is predominant cotton with the cotton comprising a minimum of 51 percent over polyester filament yarn/polyester spun yarn/polyester cotton spun yarn which will be a maximum 49 percent. The cotton yarn count can vary from 30 s to 60 s thread count and polyester filament yarn/polyester or spun yarn/polyester cotton spun yarn which can vary from 10 D up to 240 D with 14 filament to 216 filament thread count.

[0039] The polyester fibers were included in the prior art cotton percale because of the cost of the polyester yarn which was much cheaper than the cotton yarn. Hence, a product with polyester will be cheaper for the consumer, value for money in the hands of the consumer.

[0040] The polyester-cotton fabric of the present invention gives wrinkle resistance. Moreover, polyester yarn is known for its increased durability adding to the tensile strength, increased durability, dimensional stability, wear and tear performance of the fabric of the present invention thereby making it more attractive for the consumer.

[0041] Sheeting fabrics suitable for use in the present invention are of a plain weave construction with a thread count of at least about 130 threads per inch up to 2000 threads per inch. Cotton yarn count from 30 s to 60 s with 10 denier to 240 denier with 14 filaments to 216 filament, and typically have a weight range of about 80 grams per square meter to 250 grams per square meter thereby exhibiting high tensile strength. They are generally of a substantially balanced construction. The percale weave is a closed construction and is balanced with warp and weft.

[0042] The sheeting fabric in accordance with the present invention comprises a woven percale sheeting fabric having a uniform woven fabric construction of at least 130 thread count per inch up to 1200 threads per inch throughout both the sheet areas and the heavier areas. The core spun yarns have a yarn count of about 30 s to 60 s in cotton and 10 D D to 240 D of filament polyester/polyester spun yarn/polyester cotton spun yarn.

[0043] Percale sheeting fabric can be formed of a single common color, or different colors, or of multiple colors by incorporating into the print, in addition to the oxidizing agent, suitable disperse dyestuffs which sublime into the polyester core component. Polyester dyed is in disperse dyeing and cotton in reactive dyeing to match both components of fabric and the print will be in pigment dyes.

[0044] Cotton yarn will be from 30 s to 60 s yarn count made from either carded/combed/compact or Egyptian/pima/supima cotton. Percale fabric is woven with warp cotton yarn 100 percent cotton/Egyptian cotton/pima/supima cotton and weft polyester filament yarn/polyester spun yarn/polyester cotton spun yarn. In the alternative, it can be either way with warp polyester filament yarn/polyester spun yarn/polyester cotton spun yarn and weft cotton yarn 100 percent cotton/Egyptian cotton/pima/supima cotton.

[0045] In addition polyester filament yarn, polyester spun yarn and polyester cotton spun yarn are added. The polyester filament yarn may also be CVC.

[0046] FIG. 5 is a graph charting 15 denier to 240 denier polyester filament yarn against 140 thread count to 1200 thread count threads per inch of cotton rich grid. This graph demonstrates that the sweet spot is 60 percent cotton and is based on the test method AATCC 20 and 20A.

[0047] FIG. 6 is a graph charting 15 denier to 240 denier polyester filament yarn against 140 thread count to 1200 thread count threads per inch and measuring tensile strength. This graph demonstrates that the tensile strength sweet spot is 40 lbs by 40 lbs for both weft and warp as per ASTM 5034 test method.

[0048] FIG. 7 is a graph charting 15 denier to 240 denier polyester filament yarn against 140 thread count to 1200 thread count threads per inch and measuring fabric pilling grid. This graph demonstrates that the sweet spot in this test is grade 4.0 as per ASTM D4970 (100 Movement).

[0049] Note is taken of a comparison between the CVC bedding of the present invention and conventional satin CVC bedding.

[0050] a) The cotton content is more in percale weave than in satin weave, as in satin weave it is 4/1. The present invention has cotton only on the top surface and the bottom is 100 percent polyester, where in percale it is 1/1 weave so the cotton portion is there on both surfaces so percale bedding is better.

[0051] b) The tensile strength is more in percale versus satin.

[0052] c) As both surfaces are the same in the present invention, the color consistency will be much higher and even in percale as compared to satin.

[0053] d) There is also more crispness in the present invention since cotton is present on both sides in percale vs. satin.

[0054] e) Pilling is less and washing is better in percale versus satin as both surfaces are the same.

[0055] As to the manner of usage. and operation of the present invention, the same should be apparent from the above description. Accordingly, no further discussion relating to the manner of usage and operation will be provided.

[0056] With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.

[0057] Therefore, the foregoing is considered as illustrative only, of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable Modifications and equivalents may be resorted to, falling within the scope of the invention.