Abstract: A multi-color, knitted, sculpted, terry fabric is formed with two yarns on a circular double knitting machine having cylinder and dial needles by forming a ground layer by actuating the dial needles to engage both yarns, and by selectively actuating the cylinder needles to engage one or both yarns to form pile loops, or neither yarn to form no pile loops. The cylinder needles are opened upon actuation by operation of a latch opening mechanism that is moveable and biased towards an engaging position. The fabric may be held down as the cylinder needles actuate by a hold down bar. Multi-color, three-dimensional, non-repeating patterns may be formed in the fabric by using yarns of different color, and by selectively forming regions having no pile, pile loops of the first yarn, pile loops of the second yarn, and/or pile loops of both yarns.

Abstract: A fitted bed sheet having a stretchable knit construction that includes inherent elastic qualities sufficient to enable the bed sheet to be stretched over and around a mattress. Specifically, the fitted bed sheet is of a knit construction and includes a series of knitted loop courses formed by yarns knitted into a series of consecutive loops. Formed at selected intervals between the knitted loop courses is a series of intermediate courses. Each intermediate course is disposed between one or more knitted loop courses and formed by a repeating pattern of knit, miss and tuck stitches. This particular construction results in an inherently elastic or stretchable knit construction that permits the fitted sheet to be pulled and stretched over a mattress without requiring a sewn-in elastic band.

Abstract: A composite fabric includes inner and outer knitted layers which are joined by interlock stitches at predetermined intervals to form a composite fabric. The composite fabric 10 is make on a circular knitting machine having cylinder and dial needles by feeding alternating sets of the yarns to the cylinder and dial needs. The cylinder needles form an outer layer of the fabric by knitting a first set of yarns while the dial needles form the inner layer of the fabric by knitting the second set of yarns. During the knitting process, interlock stitches are formed in every course of alternating sets of wales. The interlock stitches are formed in a first set of alternating wales for a predetermined number of courses then switch to a second set of alternating wales for another predetermined number of courses.