BEDDING FOR A MATTRESS

A bedding system including one or more bedding components is provided for use with a bed. The bedding component includes a fitted sheet, a top sheet, a pillow case and/or a comforter. The fabric panel forming the bedding component may include air vents integrated into the fabric panel. Additionally, the fabric panel may further include an activatable material integrated into and/or disposed in proximity with the fabric panel.

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Description
CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No. 16/113,057, entitled “Bedding for a Mattress”, filed Aug. 27, 2018, which claims priority under 35 U.S.C. 119(e) to U.S. Provisional Patent Application Ser. No. 62/550,678, entitled “Sleep Recovery System Including Bedding Components with Air Vents and/or Bioceramics”, filed Aug. 27, 2017, the disclosures of which are incorporated herein by reference in their entireties for all purposes.

FIELD OF THE INVENTION

The present invention is directed toward bedding (e.g., bed sheets including top sheets and fitted sheets, pillow cases, comforters, etc.) that provides comfort and assists in recovery of the body during periods of sleep and rest.

BACKGROUND OF THE INVENTION

Athletic exercise and, in particular, athletic activity at an elite level (e.g., in professional and other sports), can involve periods at which a person (e.g., athlete) engages in intensive strength and/or cardiovascular performance of his or her body followed by recovery periods in which the person must rest her or her body. Advances in sport science have shown that the recovery period for an athlete is just as important as periods of exercise in maintaining body strength, health and cardiovascular fitness. Sleep over a 24-hour period is a very important component for body recovery after periods of exercise activity. For example, an elite athlete that trains for a particular sport for several hours in a given day must also engage in sufficient recovery time for his or her body, where such recovery includes a sufficient period of consecutive hours of sleep in the evening.

The average time period of sleep in a given day for a typical person (athlete or non-athlete) is about 8 hours (or at least ⅓ of the day). Given that a good night of rest is important to body recovery, a number of commercially available types of sleep aids are available to enhance a person's ability to achieve a restful sleep, where such sleep aids range from types of bedding (e.g., extra soft silk bedding sheets and/or bedding sheets with large thread counts, special types of pillows to enhance a user's head and neck position during sleep, etc.) to electronic devices that provide white (or other) noise, monitor sleep cycles, etc. to enhance and/or monitor a user's ability to fall into deep (e.g., REM) sleep.

BRIEF SUMMARY OF THE INVENTION

A bedding system for use with a bed includes one or more bedding components (e.g., fabric structures including a fitted sheet, a bed sheet, a comforter and/or a pillow case). In an embodiment, the bedding component includes air vents extending through and disposed at selected locations along the fabric structure. The bedding component may further include a ceramic material integrated with one or more surfaces of the fabric structure and/or provided with insulation material within the fabric structure (e.g., bioceramic material incorporated with insulation material within a comforter).

In an example embodiment, a sleep recovery system for use with a bed comprises a bedding component including a fabric panel including a first surface and a second surface that opposes the first surface, where the fabric panel includes a plurality of air vents formed as apertures defined at the first surface, and the fabric panel further includes a bioceramic material integrated and/or disposed in proximity with the fabric panel.

In further example embodiments, a sleep recovery system includes at least two bedding fabric structures or bedding components selected from the group consisting of a pillow case, a fitted bed sheet, a top bed sheet, and a bed comforter, where the fitted sheet comprises a plurality of fabric panels including a top panel and a plurality of side panels extending downward from the first panel to facilitate securing of the fitted sheet around a portion of the bed, the top sheet comprises a fabric panel, and the pillow case comprises a plurality of fabric panels. A panel surface of one or more of the bedding components includes at least one sleep recovery aid or feature selected from the group consisting of a plurality of air vents formed as engineered apertures in the panel surface, and a bioceramic material printed on the panel surface.

In still further example embodiments, each bedding fabric structure or fabric component can be a woven textile structure that includes a plurality of warp yarns and a plurality of weft yarns. In addition, each vent within the fabric structure can be formed as an aperture disposed at an intersection between a warp channel and a weft channel, where the warp channel is defined as an elongated gap along the warp of the textile structure, the warp channel formed by removal of a warp yarn of the plurality of warp yarns, and the weft channel is defined as an elongated gap along the weft of the textile structure, the weft channel formed by removed of a weft yarn from the plurality of weft yarns.

The above and still further features and advantages of the present invention will become apparent upon consideration of the following detailed description of specific embodiments thereof.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 illustrates a schematic view of a bedding system for use with a mattress in accordance with example embodiments of the present invention.

FIG. 2A illustrates a schematic view of a fitted sheet for the bedding system of FIG. 1, including a lower surface of a panel of the fitted sheet.

FIG. 2B illustrates a schematic cross-sectional view of a comforter for the bedding system of FIG. 1.

FIG. 2C illustrates a schematic view of a pillow case for the bedding system of FIG. 1, where the pillow case is turned inside out to reveal an interior surface of a panel that forms part of the pillow case, where a portion of a bioceramic pattern printed on the interior surface is depicted.

FIG. 3A illustrates a schematic of a woven textile for forming a bedding fabric structure for one or more bedding components of the bedding system of FIG. 1.

FIG. 3B illustrates a cross sectional view of the textile of FIG. 3A, taken along line 3B.

FIG. 3C illustrates the textile of FIG. 3A, showing dissolvable yarns within the structure.

FIG. 3D illustrates the textile of FIG. 3C, showing dissolved yarns and engineered apertures or air vents in the textile.

FIG. 4 illustrates a schematic of another woven textile in accordance with the invention, showing removal of a yarn from the structure and the formation of an aperture.

FIG. 5 is a portion of the textile structure for a bedding component of FIG. 1, showing air vents formed within the textile structure due to removal of yarns from the structure and the formation of engineered apertures or air vents in the structure.

FIG. 6 is a flowchart depicting an example process for printing a ceramic material onto a fabric surface of a bedding component in accordance with an example embodiment of the invention.

FIG. 7A depicts an example embodiment of a printed pattern that can be applied to surface portions of bedding components of the sleep recovery system of FIG. 1.

FIG. 7B is an enlarged view of a portion of the printed pattern of FIG. 7A.

Like reference numerals have been used to identify like elements throughout this disclosure.

DETAILED DESCRIPTION OF THE INVENTION

In the following detailed description, reference is made to the accompanying figures which form a part hereof wherein like numerals designate like parts throughout, and in which is shown, by way of illustration, embodiments that may be practiced. It is to be understood that other embodiments may be utilized, and structural or logical changes may be made without departing from the scope of the present disclosure. Therefore, the following detailed description is not to be taken in a limiting sense, and the scope of embodiments is defined by the appended claims and their equivalents.

Aspects of the disclosure are disclosed in the accompanying description. Alternate embodiments of the present disclosure and their equivalents may be devised without parting from the spirit or scope of the present disclosure. It should be noted that any discussion herein regarding “one embodiment”, “an embodiment”, “an exemplary embodiment”, and the like indicate that the embodiment described may include a particular feature, structure, or characteristic, and that such particular feature, structure, or characteristic may not necessarily be included in every embodiment. In addition, references to the foregoing do not necessarily comprise a reference to the same embodiment. Finally, irrespective of whether it is explicitly described, one of ordinary skill in the art would readily appreciate that each of the particular features, structures, or characteristics of the given embodiments may be utilized in connection or combination with those of any other embodiment discussed herein.

Various operations may be described as multiple discrete actions or operations in turn, in a manner that is most helpful in understanding the claimed subject matter. However, the order of description should not be construed as to imply that these operations are necessarily order dependent. In particular, these operations may not be performed in the order of presentation. Operations described may be performed in a different order than the described embodiment. Various additional operations may be performed and/or described operations may be omitted in additional embodiments.

For the purposes of the present disclosure, the phrase “A and/or B” means (A), (B), or (A and B). For the purposes of the present disclosure, the phrase “A, B, and/or C” means (A), (B), (C), (A and B), (A and C), (B and C), or (A, B and C). In addition, the phrase “at least one of A and B” means that either A or B is present or that both A and B are present.

The terms “comprising,” “including,” “having,” and the like, as used with respect to embodiments of the present disclosure, are synonymous.

A bedding system includes bedding fabric structures or bedding components configured to be implemented for use with a bed mattress. The bedding components can include any combination of a fitted sheet that fits directly over a top surface and side surfaces of a mattress when in use, a top or flat sheet that is placed over the fitted sheet when in use, one or more pillow cases (i.e., one or more sheets with sheet edges secured in a manner to form a partially enclosed pocket, cavity or enclosure therebetween and an opening at one end to receive a pillow within the pocket), and a comforter (i.e., typically a plurality of sheets connected together via stitching or in any other suitable manner to form a fully enclosed pocket, cavity or enclosure therebetween, where the enclosed pocket includes some form of insulation material) that is typically disposed over the top sheet when in use. A bedding system may include the different bedding components individually and/or in any suitable combinations, such as a bedding set which typically includes the fitted sheet, top sheet and one or more (e.g., two) pillow cases, or a comforter set which includes the comforter and the bedding set or any other combination (one or more) of the other bedding components.

The bedding components for the sleep recovery system can be suitably dimensioned to fit any conventional or other types of mattresses (e.g. square or rectangular shaped mattresses) including, without limitation, traditional king size mattresses (e.g., mattresses having dimensions of about 76 inch by 80 inch), traditional twin size mattresses (e.g., mattresses having dimensions of about 38 inches wide by 75 inches long), traditional twin size extra-long mattresses (e.g., mattresses having dimensions of about 38 inches wide by 80 inches long), traditional full size mattresses (e.g., mattresses having dimensions of about 54 inches wide by 75 inches long), traditional queen size mattresses (e.g., mattresses having dimensions of about 60 inches wide by 80 inches long), traditional king sized mattresses (e.g., mattresses having dimensions of about 76 inches wide by 80 inches long), and traditional California king sized mattresses (e.g., mattresses having dimensions of about 72 inches wide by 84 inches long), or any custom or non-standard size mattress constructions.

Referring to FIG. 1, an example embodiment of a bedding system 10 includes one or more bedding components including a fitted sheet 20, a top sheet 30, a comforter 40 and two pillow cases 50, where each of the fitted sheet 20, the top sheet 30, and the comforter 40 is suitably dimensioned to fit over a portion of a mattress 70 while each pillow case 50 is suitably dimensioned to contain or encase a pillow (not shown).

The fitted sheet 20 of the bedding system 10 comprises a plurality of panels including a top panel and a side panel extending from each side of the top panel, where an interior or lower surface of the top panel faces a direction at which each side panel extends from the top panel, and an upper or user-facing surface 28 of the top panel faces away from the direction at which each side panel extends from the top panel. In particular, referring to FIG. 1, the fitted sheet 20 includes a top panel or body 26 defining a top side of the fitted sheet, two side or lateral panels 22 disposed at opposing lengthwise ends or lengthwise side edges of the top panel 26, and two length side panels 24 (e.g., an upper side panel and a lower side panel) disposed along opposing widthwise ends or widthwise side edges of the top panel 26. The side panels 22, 24 may be formed integrally with the top panel 26 or, as illustrated, may be separate panels connected to the top panel via stitching. The top panel 26 defines an upper (user-facing) surface 28 that faces a user when the fitted sheet 20 is placed onto the mattress 70. The top panel 26 further includes a lower or underside surface 27 (see FIG. 2A) that faces away from the user and toward the mattress when the fitted sheet 20 is placed onto the mattress 70. With this configuration, the fitted sheet 20 defines an open cavity between the top panel 26 and side panels 22, 24. Thus, when the fitted sheet 20 is fit over the mattress 70, a portion of the mattress fits within the fitted sheet cavity and the lower surface 27 of the fitted sheet 20 lies substantially adjacent or in close proximity with (e.g., contacts) a top or facing surface of the mattress 70, with each side panels 22, 24 engaging a corresponding side wall of the mattress.

Resilient material can be provided at or along the lower or distal edges 25 of the side panels 22, 24 of the fitted sheet 20 that stretches and conforms to the sides of the mattress 70 when the fitted sheet 20 is secured over the mattress. In an example embodiment, the resilient material comprises an elastic fabric band 23 disposed along the distal or bottom end 25 of the side panels, spanning the circumference of the sheet 20. Additionally, disposed on the interior surface of the fabric band 23 is a layer or film 25 of a resilient, tacky (high friction) polymer operable to frictionally engage the mattress surface. The polymer is an elastomeric polymer or an elastomer. The high friction polymer includes, but is not limited to, silicone rubber. The elastomer increases the frictional forces between the band 23 and the mattress, maintaining the sheet thereon. In addition, the polymer may increase the recovery power of the band 23, increasing the biasing force against the mattress. The film covers a portion of the interior (mattress-facing surface) of the band. In an embodiment, the film covers 10%-60% of the interior surface area of the band 23 (e.g., the height of the band). Coverage less than this may result in poor surface engagement, while coverage above this range inhibits the stretch of the band. With this configuration, the band 23 expands (stretches) for positioning on the mattress, but then retracts to place the inner surface of the band in contact with the mattress, biasing the band in contact therewith.

This further enhances the engagement between the fitted sheet and the mattress to limit or prevent movement of the fitted sheet in relation to the mattress when the fitted sheet is placed onto the mattress. In other words, the resilient band and the silicone film form a continuous resilient composite structure around the lower or bottom edges of the side panels (and therefore also around the entire peripheral dimensions of the fitted sheet) capable of enhancing the securement and frictional fit between the fitted sheet and the mattress to which the fitted sheet is secured. This is in contrast with conventional sheets which lack the film of high friction polymer.

The top sheet 30 comprises a body with and upper trim or header disposed along the top edge of the body, a first lateral trim and a second lateral trim along the lateral edges of the body, and a bottom trim along the body edge of the body. The body and trims cooperate to define a bottom or user-facing surface 32 and a top or opposing surface 34 (i.e., the upward facing surface). The body may be a single layer of fabric (e.g., a non-stretch woven fabric). The trim, in contrast, possesses a two-layered fabric construction formed by, e.g., by folding the body fabric over on itself. As shown in FIG. 1, the top sheet 30 rests over the fitted sheet 20 when applied to the mattress 70, where the user-facing surface 32 is facing downward toward the user and mattress. During typical use, a user rests on the mattress 70 between the fitted sheet 20 and the top sheet 30.

The comforter 40 comprises two fabric panels, in particular a first or bottom panel 42 and a second or top panel 44, where the two panels are secured together at their edges in any suitable manner (e.g., via stitching) to define a full enclosure or a closed cavity between the panels 42, 44. At least the bottom panel 42 includes an outer, user-facing surface 43. Referring to FIG. 2B (which depicts a cross-section of the comforter 40), disposed along an interior or enclosure-facing surface 47 of each panel 42, 44 is a mesh or scrim layer 45. Disposed within the enclosure is an insulation material that comprises a combination of mixed fibers or filaments 46 with insulating properties, including bioceramic fibers (described in greater detail below). In use, the comforter 40 is typically placed over the top sheet 30 with user-facing surface 43 facing downward (toward the mattress 70 and the user).

The mesh or scrim layer 45 can comprise a suitable textile material (e.g., polyester) having opening or pores of a suitable size so as to provide a desired porosity to the layer 45 while substantially minimizing or preventing passage of bioceramic material and/or insulation material (e.g., in the form of fibers) through the layer 45. In other words, the mesh or scrim layer 45 substantially limits or prevents passage or escape of insulation material from the enclosure or cavity defined between the panels 42, 44 of the comforter 40. By way of example, the scrim may be a textile such as a nonwoven textile formed of natural strands (yarns or filaments), or of synthetic strands (yarns or filaments) such as polyethylene terephthalate (PET). In an embodiment, the scrim possesses a basis weight in the range of 2 gsm (grams/m2) to 30 gsm, such as a range of 5 gsm to 20 gsm (e.g., 7 gsm).

Each pillow case 50 includes two panels, an upper panel 52 and a lower panel 54, that are secured at their edges in any suitable manner (e.g., via stitching), with the exception that the edges of the two panels are not secured together at one lengthwise end 55 of each pillow case. This configuration defines a cavity or partial (i.e., not fully enclosed) enclosure between the two panels 52, 54 within which a pillow can be inserted and enclosed by the pillow case. Each of the upper panel 52 and lower panel 54 includes an outer or user-facing surface 58. As depicted in FIG. 2C (where a pillow case 50 is turned inside out), each of the upper and lower panels 52, 54 also includes an interior or cavity facing surface 57 (i.e., an underside surface to the user-facing surface). In use, the user typically rests his or her head on the pillow enclosed in a pillow case 50 with the upper panel outer surface 58 facing toward the user's head. As described in further detail herein, each pillow case can be configured such that its panels can serve as an upper panel 52 or lower panel 54 depending upon how the pillow case is aligned in relation to the user's head during use. Alternatively, each pillow case can be configured such that the upper panel 52 is different from the lower panel 54 (where the two panels are clearly marked or identified so that the user can correctly align the upper panel 52 toward the user's head during use).

While certain bedding components have been described herein as including certain panels, it is noted that similar bedding components can also be constructed with fewer or more panels for a particular application. Further, the thickness of the fabric panels or fabric sheets forming the bedding components can be of any conventional or other suitable thicknesses and/or utilizing any suitable range of thread counts along a given area of the fabric panel or sheet.

The bedding components 20, 30, 40, 50 of the system 10 are formed of a textile including strands manipulated such that they interlock. In an embodiment, the strand is a yarn having a substantial length and small cross-section and is typically formed from one or more filaments or fibers. Filaments have an indefinite length and can be formed of synthetic polymers and/or natural materials (e.g., silk, cotton). Yarns can be formed from filaments having the same or different materials. Fibers, by comparison, have a relatively short length and require spinning or twisting processes to produce a yarn of suitable length. Common examples of fibers are cotton and wool. As with filaments, yarns may be formed from fibers of the same or different materials. The yarn forming the textile structure can be formed of any one or more combinations of filaments and/or fibers.

Some example types of polymers or other (e.g., natural) materials for forming filaments used to create yarns for the textile structures of the bedding components include, without limitation, polyesters (e.g., polyethylene terephthalate or PET, polybutylene terephthalate or PBT, etc.), polyolefins (e.g., polyethylene and polypropylene), polyamides (e.g., Nylon), processed cellulose (e.g., rayon, lyocell or cotton), polylactic acid (PLA), polyvinyl alcohol (PVA), polyurethanes, and any suitable combinations or copolymers thereof. The selection of particular types of polymers can provide different properties to the filaments and, in turn, to the yarns formed from such filaments. For example, filaments formed from different polymer materials can impart different degrees of elasticity or elastomeric/stretch properties to the yarns and the textile structure formed of the yarns.

Several types of yarn may be utilized to form textile structures for bedding components. Spun yarn includes a number of fibers twisted together. Zero-twist yarn includes a number of filaments laid together without twist. Twist yarn includes a number of filaments laid together with a degree of twist. A monofilament yarn includes a single filament with or without twist.

The textiles may be produced through various production methods, including nonwoven processes, knitting processes, and weaving processes. Nonwoven textiles are webs of filaments or fibers connected via bonding, fusing, or interlocking. Knit textiles include consecutive rows of loops of filaments or fibers, called stitches. As each row progresses, a new loop is pulled through an existing loop. Woven textiles include a set of lengthwise threads (called the warp) interlaced with a set of crossing threads (called the weft). Knitted textiles are loose, including spaces between the loops that permit air to pass therethrough. Accordingly, the knitting process forms a highly breathable fabric. In contrast, woven textiles, while strong and durable, are dense and tight. Conventional woven textiles therefore possess poor breathability and poor air permeability.

In accordance with embodiments of the invention, the textile includes an array of apertures or openings formed integrally into the textile structure of the bedding component, the apertures permitting fluid flow (e.g., airflow) through the bedding component. In conventional bedding, a layer of knit spacer fabric or a knitted mesh layer is typically provided as an additional layer in composite structure (e.g., the mesh or spacer is enclosed in a knitted shell to provide a breathable system). Such additional layers increase the weight of the structure, as well as the costs of formation. In contrast, the apertures according to an embodiment of the invention are incorporated into a single fabric layer, e.g., by selectively removing strands or strand portions from the textile structure.

In example embodiments, the textile structure forming the fabric sheets and/or fabric panels of the bedding components is a woven textile structure. In weaving, two or more yarns are interlaced so that the yarns they cross each other at substantially right angles to produce woven fabric. The warp yarns (ends) run lengthwise (longitudinally) in the fabric, while the weft yarns (filling threads or picks) run from side to side (transversely) in the fabric. The set of lengthwise yarns or threads (called the warp) are interlaced with a set of crossing threads (called the weft) via a loom. Several types of weaving patterns may be utilized to form the textile structure. In plain weaving, the warp and weft are aligned so they form a simple crisscross pattern. Specifically, each weft thread crosses the warp threads, with a first warp thread alternately going over one warp thread and under the adjacent warp thread. The adjacent weft thread inverts this process, with the weft thread crossing under the warp thread the previous thread crossed over. A basket weave, similar to the plain weave, includes two or more warp and filling threads woven side by side to resemble a plaited basket. In a satin weave, the face of the fabric consists almost completely of warp or filling floats produced in the repeat of the weave. A twill weave is characterized by diagonal lines produced by a series of floats staggered in the warp direction. A double weave includes two systems of warp or filling threads combined such that only one is visible on either side. A leno weave includes warp yarns arranged in pairs, with one warp yarn twisted around another warp yarn between picks of filling yarn.

In accordance with embodiments of the invention, the textile structure forming the bedding components 20, 30, 40, 50 is a woven structure including by a plurality of weft runs or yarns and a plurality of warp runs or yarns. After formation of the woven textile, selected warp and weft runs (the yarns defining the run) are removed to form warp channels and weft channels, respectively. Accordingly, a warp channel is positioned between warp yarns (separating the warp yarns in the textile) and a weft channel is positioned between weft yarns (separating the weft yarns in the textile). As a result of the channels, the textile structure includes areas having both warp and weft yarns, areas having only one of warp or weft yarns, and areas having neither warp nor weft yarns. The areas lacking one or both of the warp yarns and the weft yarns define apertures forming air vents that improve the air permeability and/or the breathability of the textile.

The warp and/or weft yarn may be removed in a non-mechanical manner. In an embodiment, the yarns are removed chemically, e.g., via dissolution in a solvent. Typically, the entire warp and or weft yarn is removed such that the channel extends the entire length and or width of the textile structure. This process and the resulting aperture structure may be distinguished from other, conventional aperture-forming processes. For example, the aperture formation process of embodiments of the invention may be distinguished from mechanical processes that form a discrete opening in a fabric, e.g., by means such as punching or cutting. The opening may further be distinguished from openings existing as a result of the textile formation process (e.g., a weaving or knitting process) where the opening results from the stitch pattern and not from processing after the formation of the textile (e.g. a knit mesh fabric). Accordingly, the textile structure forming bedding components includes a plurality of engineered apertures or air vents that improve the air permeability and/or the breathability of the textile. An engineered aperture (also called a dissolution void) provides an opening or dissolution void in the woven textile structure, which is created by removal of one or more weft yarns and/or one or more warp yarns from the structure. In particular, an engineered aperture is an opening formed by removing intersecting weft and warp yarns. For example, the yarns may be removed in a non-mechanical manner. In an embodiment, the yarns are removed chemically, e.g., via dissolution in a solvent. The apertures pass completely through the textile structure to permit fluid (air and/or water vapor) to pass therethrough. Thus, an engineered aperture or air vent in the textile structure for a bedding component is not a discrete opening in the fabric formed mechanically, e.g., by means such as punching or cutting. An engineered aperture, moreover, is not an opening existing as a result of the textile formation (e.g., a weaving or knitting process) such as a mesh fabric. Furthermore, an engineered aperture is not an opening formed by changing a physical parameter of the yarns, e.g., by changing yarn dimensions (e.g., via water absorption). Finally, an engineered aperture is not an opening formed by etching with a mask. In etching, caustic chemical action removes a discrete area of the fabric to form the opening. The etchant merely breaks the weft or warp yarn—the weft or warp yarn is not completely removed.

Referring to FIGS. 3A-3D, a textile structure 300 that forms a portion (e.g., a sheet or panel) of a bedding component is formed via weaving and thus includes a plurality of weft yarns 305 (aligned in the direction WWEFT as shown in FIG. 3A) interwoven with a plurality of warp yarns 310 (aligned in the direction WWARP as shown in FIG. 3A) such that the warp and weft yarns cross at substantially right angles to each other. As best seen in FIG. 3C, the plurality of weft yarns 305 includes dissolvable yarns 315A and inert yarns 315B. Similarly, the plurality of warp yarns 310 includes both dissolvable yarns 320A and inert yarns 320B.

The dissolvable yarn can be formed from one or more filaments that are water soluble, such as polyvinyl alcohol (PVA) or a modified, water-soluble polyester. Other types of dissolvable yarns can also be utilized including, without limitation, cellulose fibers or filaments (e.g., rayon, lyocell, and cotton) or a polyamide fiber or filament (e.g., 6,6-nylon) that are dissolvable in a solvent including aluminum sulfate or acid sodium sulfate, or a modified polyester fiber or filament that is dissolvable in a solvent including sodium hydroxide. The inert or non-dissolvable yarn is formed of filaments or fibers that do not dissolve in the solvent that is used to dissolve the removable yarns. In an example embodiment, the two types of yarns used for forming textile structures for bedding components include inert/non-removable yarns formed from a non-dissolvable polyester material and dissolvable/removable yarns formed from a dissolvable polyester material (i.e., a modified polyester material that differs from the polyester material used to form the non-removable yarns) that dissolves in an aqueous solvent (e.g., water).

After the formation of the textile structure 300, the dissolvable yarns 315A, 320A and inert yarns 315B, 320B are exposed to a suitable solvent or dissolving agent. The dissolving agent may be applied via any process suitable for its described purpose (i.e., to apply the agent such that it contacts the entire textile and forces dissolvable yarns 315A, 315B into contact with the dissolving agent) including, without limitation, spraying the dissolving agent onto the textile structure, drawing the textile structure through a solution or bath containing the dissolving agent, etc. After exposure of the textile structure 300 to the dissolving agent (as shown in FIG. 3D), the inert yarns 315B, 320B remain intact, while the dissolvable yarns 315A, 320A dissolve in the dissolving agent (i.e., the yarns fall into solution with the solvent). This results in the selected yarns (i.e., the dissolvable yarns 315A, 320A) being removed from the textile structure 300 while leaving an elongated weft channel or gap 325 and an elongated warp channel or gap 330 where the yarns 315A, 320A previously existed. The channels 325, 330 form the apertures for the textile structure 300 which function as the air vents for a bedding component. As illustrated, the entirety of the warp and/or weft warn is removed from the textile structure 300.

The ratio of inert yarns to dissolvable yarns may be any suitable for its intended purpose (to create a textile structure). In an embodiment, the ratio of inert yarns to dissolvable yarns is from approximately 10:1 to approximately 7:3. Stated another way, the structure may include 10% to 50% dissolvable yarns (e.g., 20% to 40% or, by way of further example, approximately 33%). Structures with over 50% dissolvable yarns begin to weaken the textile. The arrangement of the yarns within the structure may also be selected to provide the desired level of breathability and strength in the textile. In each of the warp direction and weft direction, the textile structure may include a plurality of dissolvable yarns positioned between a first and second pluralities of inert yarns, the first and second pluralities being adjacent the plurality of dissolvable yarns.

The resulting textile structure includes areas of differing yarn combinations. Specifically, it includes a first area or portion 405 including both warp and weft yarns, a second area 415 including only warp yarns (i.e., where all the weft yarns are removed), and third area 410 including only weft yarns (i.e., where all the warp yarns are removed), and a fourth area 420 including no yarns (i.e., no warp or weft yarns). With this configuration an array of openings is formed including rows of apertures oriented along lines running orthogonal to each other (i.e., a grid pattern of apertures is formed). In addition, as shown in FIG. 3D, two types of apertures are formed: a first or small aperture 335 possessing a first dimension or diameter and a second or larger aperture 340 possessing a second dimension or diameter, the second dimension being greater than the first dimension. In general, the small apertures 335 exist along those areas 410, 415 where only the weft yarn 305 or warp yarn 310 is removed. The large engineered aperture 340 exists at the intersection of the warp channel and the weft channel (i.e., the area 420 where the weft 305 and warp 310 yarns are removed).

Thus, the embodiment depicted in FIGS. 3A-3D describes an embodiment in which engineered apertures of varying sizes can be selectively placed at desired locations of the textile structure 300 based upon the placement of dissolvable/removable yarns 315A and inert/non-removable yarns 315B within the textile structure. Depending upon the orientation or placement of different yarns at selected locations of a textile structure, engineered apertures can be formed of varying sizes (e.g., one or more sizes), varying shapes (e.g., one or more different shapes, including polygon such as rectangular or square, round, oval, irregular shaped, etc.). For example, in another embodiment depicted in FIG. 4, either weft yarns or warp yarns may be removed from the textile structure (instead of both warp and weft yarns being removed as depicted in FIGS. 1A-1D). In particular, a dissolved warp yarn 320A (shown in phantom) is illustrated in FIG. 4, which results in the formation of engineered apertures having the same or similar shapes and dimensions along the warp direction of the textile structure. Other embodiments are also possible, including warp and weft yarns with different combinations of dissolvable and non-dissolvable yarns (e.g., any number of dissolvable warp or weft yarns provided in succession and adjacent to each other and separated by any number of non-dissolvable warp or weft yarns in succession).

Depending upon the placement and grouping of different warp and weft yarns that are dissolvable/removable and non-dissolvable/non-removable, the formation of engineered apertures form air vents defined by the gaps formed by dissolved yarns from the textile structure. Thus, air vents can be formed or defined in any arrangement, shapes, sizes and/or patterns in a bedding component utilizing the techniques for forming engineered apertures as described herein. For example, air vents/engineered apertures can be formed in bedding components having sizes ranging from a dimension (e.g., length and/or width dimension, or a diameter) that is 10 mm (millimeters) or less, such as 5 mm or less, or 1 mm or less, or even 0.10 mm or less. In some embodiments, small air vents can be formed in a bedding component having a dimension that is 0.10 mm or less, while larger apertures can also be formed in the bedding component having a diameter greater than 0.10 mm (e.g., 0.20 to 5 mm or greater).

In certain embodiments, the air vents are formed by completely dissolving and removing one or more warp and/or weft yarns from a bedding component, such that air vents may be defined along in a linear direction at which the warp and/or weft yarn(s) were located prior to being completely dissolved and removed from the bedding component. For example, air vents can be formed along the entire linear dimension of a bedding component (e.g., along the entire length and/or entire width of the bedding component), where rows and/or columns of air vents can be defined (e.g., in a crossing pattern or array) along a surface and/or through a panel of a bedding component.

Referring to FIG. 5, the resulting textile structure 300 forming the bedding component includes a sheet or panel 500 with weft channels 325 and warp channels 330 formed by removal of the corresponding plurality yarns as described above. The large apertures 540 are disposed at the intersection between weft channels or gaps 325 and warp channels or gaps 330. The areas 410, 415 of the channels 325, 330 between the large apertures 340 include the smaller apertures 335 formed by the spacing between adjacent yarns.

Stated another way, along the longitudinal axis of the weft channel 325 (where the weft yarn is removed) is the second area 415 in which warp yarns intersect and span the weft channel (e.g., intersecting the channel at approximately 90 degrees). This area includes the smaller apertures 335. In addition, the weft channel 325 includes the fourth area 420 where no warp yarn intersects the weft channel (i.e., neither warp nor weft yarns are present in the fourth area). This fourth area 420 defines the large aperture 340. Similarly, along the longitudinal axis of the warp channel 330 (where the warp yarn is removed) is the third area 410 in which weft yarns intersect and span the warp channel (intersecting the warp channel at, e.g., approximately 90 degrees). This area includes the smaller apertures 335. In addition, the warp channel 330 includes the fourth area 420 in which no weft yarn intersects the warp channel (i.e., neither warp nor weft yarns are present in the fourth area). Areas outside of the channels 325, 330 include both warp and weft yarns that are interlocked with each other at selected points along their respective lengths.

Conventional woven textiles, while strong and durable, are dense and tight and therefore have poor breathability and/ poor air permeability. Breathability is the ability of a fabric to allow moisture vapor to pass through it. Air permeability, in contrast, relates to the porosity or the ease with which air passes through the textile. Both air permeability and breathability influence the comfort, warmth, or coolness of a fabric. For bedding components, this can affect the degree of restfulness a user achieves while sleeping (e.g., if the user becomes too warm or too cold while under the bed sheets/comforter). Incorporating apertures or openings (air vents) into the bedding components can facilitate breathability, permeability and/or temperature regulation to enable the user's body to be at an appropriate temperature during sleep which in turn enhances uninterrupted, deep sleep for the user to potentially maximize body rest and recovery effects during sleeping periods. The textile structure deceived, moreover, permits formation of air vents integrated into a single layer panel without damaging the integrity of the textile structure (which occurs during punching).

In another embodiment, the bedding may include an activated or functional print applied to a surface of the panels forming the bedding components 20, 30, 40, 50. Activated or functional prints are prints containing compounds that interact with the user or the heat generated by the user to insulate, absorb heat, generate and direct IR rays back to the user and/or control skin or air temperature surrounding the body. In a first example, ceramic materials capable of interacting with body heat are utilized. These ceramic materials include ceramic oxide materials and non-oxide ceramic materials including, without limitation, silicon oxides or silica (e.g., SiO2), zirconium oxides (e.g., ZrO2), titanium oxides (e.g., TiO2), aluminum oxides (e.g., Al2O3), magnesium oxides (e.g., MgO), yttrium oxide (Y2O3), zirconium carbide (ZrC), and titanium carbide (TiC), and combinations thereof. In a further example, selected ceramic materials described above are capable of absorbing heat energy radiated by the user and using the heat to generate IR radiation (e.g., far IR radiation) that is directed back toward the user. These materials are known as bioceramic materials.

A functional print can be applied as a layer onto a surface of a bedding component 20, 30, 40, 50 in any suitable manner. In an example embodiment, the functional materials of the print are incorporated into an ink composition that is printed onto one or more surfaces of the bedding component 20, 30, 40, 50. For example, a bioceramic composition includes a bioceramic material (described above) and a binder effective to disperse the components and/or to adhere the temperature reactive components to a substrate (e.g., to the yarns/fibers forming the substrate). The binder may be an elastomeric material possessing good elongation and tensile strength properties. Elastomeric materials typically have chains with high flexibility and low intermolecular interactions and either physical or chemical crosslinks to prevent flow of chains past one another when a material is stressed. In an embodiment, polyurethane (e.g., thermoplastic polyurethane such as polyester-based polyurethane) is utilized as the binder. In other embodiments, block copolymers with hard and soft segments may be utilized. For example, styrenic block copolymers such as a styrene-ethylene/butylene-styrene (SEB S) block copolymer may be utilized.

In an ink form, the amount of bioceramic material within the ink can range from about 2% by weight to about 50% or greater by weight. For example, the amount of bioceramic material within the bioceramic ink can be in an amount of at least about 2% by weight, by at least about 5% by weight, by at least about 25% by weight, by at least about 30% by weight, but at least about 40% by weight, or by no greater than about 50% by weight. In another example, the amount of bioceramic material within the bioceramic ink can be in an amount of about 5% by weight to about 15% by weight, or from about 8% by weight to about 12% by weight (e.g., about 10% by weight).

The bioceramic composition is applied to the substrate in a manner that maintains the integrity of the components and preserves properties of the substrate (the textile or fabric). In an embodiment, the bioceramic composition transferred to the substrate via printing process. By way of example, the composition is transferred to the textile or substrate via a rotogravure apparatus including an impression roller, a gravure or etched cylinder, and a tank. The cylinder is engraved/etched with recessed surface cells in a desired pattern. The tank holds the bioceramic composition. The apparatus further includes a doctor blade operable to remove excess composition from the cylinder. In operation, as the cylinder rotates, a portion of the cylinder becomes immersed in the bioceramic composition stored in the tank. The composition coats the cylinder, becoming captured within the cells. The cylinder continues to rotate, moving the coated cylinder past the doctor blade, which removes excess composition from the cylinder. The textile is directed between the impression roller and the cylinder such that the inner surface of the substrate (e.g., what will be the wearer-facing side of the apparel) contacts the cylinder. Specifically, the impression roller applies force to the substrate, pressing the textile onto the cylinder, thereby ensuring even and maximum coverage of the bioceramic composition. Surface tension forces pull the composition out of the cells, transferring it to the substrate. Once the composition is transferred, the coated textile may pass through one or more heaters to evaporate the solvent, thereby drying the composition and forming the dry print layer. If a thicker coating is desired, additional passes through the rotogravure apparatus may be completed.

An example process for printing a layer of a bioceramic material on a surface of a bedding component (e.g., on the lower surface 27 of the fitted sheet 20 and/or an interior surface 57 of the pillow case 50) is now described with reference to the flowchart of FIG. 6. At 610, a bioceramic ink material is provided, such as an ink comprising a bioceramic composed of SiO2 and/or TiO2. As noted above, the bioceramic ink can be formed by providing the bioceramic material in powder form (e.g., powder having a particle size on the order of about 10 micrometers or less, such as about 5 micrometers or less, or about 1 micrometer or less) within a suitable ink liquid formulation that facilitates suitable dissolution and/or dispersion of the bioceramic material within the liquid formulation.

At 620, the bioceramic ink is applied to a surface of the bedding component using a suitable printer. In addition to the above, further examples of suitable printers are ink jet printers, screen printers, impression or foil printers, or any other conventional or other type of printer suitable for application of the bioceramic ink. The bioceramic ink can be applied in any selected pattern or array and further in any selected amount of coverage on the bedding component surface. Thus, printing of the bioceramic ink on the bedding component fabric surface will result in one or more covered areas on the fabric surface that include bioceramic material and one or more non-covered/non-printed areas on the fabric surface (discussed in greater detail, below).

At 630, after application of the bioceramic ink to the bedding component fabric surface, the ink is dried and/or set, resulting in the bioceramic material being adhered to and integrated with the fabric surface. Depending upon a particular application and the type of bioceramic ink being applied, the drying/setting of the ink can be enhanced by heating the surface to a suitable temperature.

The process parameters of the printing process can be selectively controlled so as to achieve a desired printed pattern of bioceramic material on the bedding component fabric surface in any suitable amount. For example, surface coverage by the ceramic ink can be from about 5% to about 90% of the total surface area, such as about 20% to about 80% of the total surface area, or about 30% to about 60% of the total surface area, or 50% or greater of the total surface area (or 50% or less of the total surface area). Further, the bioceramic material can be applied at any suitable thicknesses so as to achieve a desired amount of bioceramic material within a given area. For example, surface coverage can be achieved that is from about 0.5 g/yd2 (square yard) to about 30 g/yd2, such as from about 2 g/yd2 to about 4 g/yd2, from about 4 g/yd2 to about 8 g/yd2, from about 4 g/yd2 to about 6 g/yd2, or from about 6 g/yd2 to about 8 g/yd2.

It has been determined that, for the bedding components 20, 30, 40, 50, it is possible to provide a smaller amount of ceramic material by spreading the ceramic ink out to a larger surface area (e.g., 50% or greater, 60% or greater, 70% or greater, or even 80% or greater coverage of the total surface area) while reducing the amount per area (e.g., from about 4 g/yd2 to about 6 g/yd2, or even from about 2 g/yd2 to about 4 g/yd2) to achieve the same or even further enhanced sleep recovery effects as thicker coatings (those greater than 6 g/yd2). Thicker coatings affect not only the hand of the material, making it feel coarse, but also the fabric's ability to drape. Decreasing an amount of ceramic material per area (e.g., decreasing the thickness or stacking of ceramic material in a printed layer and/or the g/yd2 amount within printed areas) provides the benefit of reduction in scattering and/or enhanced focusing of IR light reflected and/or emitted toward the user's body, which in turn enhances sleep recovery properties for the bedding component. For example, it has been determined that a printed bioceramic layer on a fabric panel surface that covers about 80% or greater of the total surface area for the fabric panel surface and has a coverage of about 2 g/yd2 to about 4 g/yd2 provides the same or similar or even more enhanced sleep recovery properties (e.g., reduced scattering and/or enhanced focusing of IR light reflection and/or emission) as compared to a printed bioceramic layer on a fabric panel surface that covers about 50% or greater of the total surface area for the fabric panel surface and has a coverage of about 4 g/yd2 to about 6 g/yd2.

The application or print pattern for the functional layer can be of any suitable types, such as a pattern of repeating and/or nested patterns of segments printed as a layer on the fabric surface. Any types of shapes (e.g., circular shapes, polygonal shapes, and irregular shapes) of bioceramic material printed as layers on the fabric surface. The pattern is a discontinuous pattern including printed areas interrupted by non-printed areas, and vice versa. Printed areas are those areas covered with the function (e.g., bioceramic) composition (applied as, e.g., a coating, film or print). Non-printed areas are those areas free of the functional (e.g., bioceramic) composition (i.e., not covered by the bioceramic composition), thereby leaving the textile exposed. The textile includes the textile itself, or the textile with coatings other than the functional composition (e.g., an antimicrobial coating, a durable, water-resistant coating, etc.).

In general, the pattern includes an arrangement of printed segments spaced apart by non-printed segments, called hinges. Each segment and hinge may possess any dimensions suitable for its intended purpose. In addition, the segments and hinges may be ordered into cells or units defining a repeating or random pattern across the textile surface. By way of specific example, the bioceramic composition printed pattern includes substantially linear segments arranged in a spaced apart and non-parallel manner in relation to each other to define selected angles (e.g., angles that are at 90° or greater, such as obtuse angles) between the linear segments. Additionally, the cells may include concentrically aligned or nested patterns of such linear segments. The nested patterns can include polygonal shapes (e.g., polygons having four or more sides, e.g., squares or rectangles, pentagons, hexagons, etc.) that are nested within the same or similar polygon shapes. The linear segments can be of the same or similar width and/or thickness or, alternatively, can have different widths and/or thicknesses.

As depicted in FIGS. 7A and 7B, the discontinuous pattern 700 includes an array of cells 701, each cell generally including nested hexagons. Specifically, each cell 701 includes a first or outer hexagon 702 surrounding a second or inner hexagon 704, with the hexagons spaced from each other by a cell hinge 703. The outer hexagon 702 is formed by six linear segments 710A, 710B, 710C, 710D, 710E, 710F, with adjacent segments being separated from each other by a segment hinge 715. The inner hexagon 704 may be a series of individual segments or, as illustrated, one continuous segment. The inner hexagon 704 may optionally include a central space or dot 708 that is free of bioceramic print. Each cell 701 is separated from adjacent cells by a border hinge 720. As shown, the segment hinge 715 and the border hinge 720 may be a narrower, minor (or micro) hinge in comparison to the cell hinge 73, which is a wider, major (or macro) hinge.

As noted above, the hinges 703, 715, 720 are areas to which no bioceramic print has been applied, while the segments 710A-710F of the hexagons 702, 704 are printed areas. Areas that are printed are generally less flexible than non-printed areas. Accordingly, the textile structure (the base fabric) is free to flex along the hinge lines relative to the printed segments. With this configuration, the hinges 703, 715, 720 maintain the fold or drape of the base fabric (and thus the bedding component), allowing it to flex/move along the hinges 703, 715, 720.

In example embodiments detailed below, it should be noted that the bioceramic material layer may be printed on a surface of a bedding component 20, 30, 40, 50 that, in use, does not come in direct contact with the user's body. For example, in certain embodiments, a bioceramic material layer is printed on the lower surface 27 of the fitted sheet 20 (e.g., as depicted in FIG. 2A), on one or more interior or enclosure facing surfaces 47 of the comforter 40, one a surface of the top sheet 30 that will be oriented in use so as to not be placed against a user's body (e.g., surface 34 of top sheet 30 as shown in FIG. 1) and/or on one or more interior or cavity facing surfaces 57 of each pillow case (e.g., as depicted in FIG. 2C). As depicted in FIGS. 2A and 2C, the pattern 700 can be applied to the lower surface 27 of the fitted sheet 20 and/or the interior surface 57 of the pillow case 50 (e.g., to some or all of these surfaces). In addition, this pattern can also be applied to the interior surface 47 of the panels 42, 44 of the comforter 40. In these embodiments, the bioceramic material layer is located on a layer that lies near but does not come into contact with the user's body, so as to maintain the integrity of the bioceramic material layer while also maintaining a desired comfort level of the bedding components during use. Providing the bioceramic material layer at such locations on surfaces of bedding components still results in the imparting of beneficial properties in relation to reflection and/or emission of IR light toward the user's body as well as enhancing body wellness and recovery.

As an alternative to (or in addition to) printing or applying the bioceramic material as a layer on the fabric surface of a bedding component, bioceramic materials can also be incorporated within filaments, fibers and/or yarns of the fabric forming the bedding component (e.g., integrated as part of a yarn material used to form a bedding component, or provided within a mat of material within the bedding component). Some examples of bioceramic fibers, filaments or yarns that can be integrated within bedding components of the bedding system include, without limitation: a polyethylene terephthalate (PET) fiber including one or more bioceramic particles (e.g., silicon oxide and/or aluminum oxide) embedded in the core of the fiber, such as fibers commercially available under the trade name CELLIANT® (Hologenix, LLC, California); a polyamide (e.g., nylon 6,6) yarn incorporated with bioceramic particles (e.g.,), such as a bioceramic yarn commercially available under the trademark EMANA® (Solvay Group, Belgium); and a combination of cotton and bioceramic yarn, such as is commercially available from SAMINA® (Germany).

For example, yarns including a bioceramic material can be provided for forming a woven, knitted, nonwoven or any other type of fabric material used to form a bedding component. The number, types and placement of yarns including bioceramic material within the fabric material can be selectively controlled to achieve a desired amount of bioceramic material per unit of fabric (e.g., about 0.5 g/yd2 to about 30 g/yd2) at selected locations within the fabric material. Further, the fabric material forming a panel or sheet of the bedding component can include any selected number of layers of intertwined yarns, with yarns including bioceramic material being disposed at any selected locations throughout the thickness of the fabric material. The filaments including bioceramic material can be provided within a fabric structure that defines a portion of a bedding component so as to be positioned at any one or both surfaces of the bedding component as well as disposed within the fabric structure of the bedding component.

The fibers, filaments and/or yarns including a bioceramic material can also be provided within the insulation material of the comforter 40. Referring to FIG. 2, the insulation material 46 disposed between panels 42, 44 of the comforter 40 includes down material and/or other insulation fibers, such as polyester staple fiber material commercially available under the trademark STRATOFIBER®. Any other suitable types of insulation material can also be provided (e.g., wool). The insulation material 46 further includes fibers, filaments and/or yarns including a bioceramic material, such as fibers that include a bioceramic material. The amount by weight of bioceramic material within the insulation material can be any selected amount to achieve a desired effect, such as bioceramic material in the insulation material in an amount from about 5% to about 80% by weight of the insulation material, or about 10% to about 60% by weight of the insulation material, or no greater than 50% by weight of the insulation material.

Bioceramic materials integrated within the bedding components (e.g., via the above printed layer) may enhance body recovery for a user during sleep by interacting with (e.g., reflecting and/or emitting) infrared or IR light (i.e., light having wavelengths from about 700 nanometers to about 1 millimeter, such as far infrared or FIR having wavelengths from about 15 micrometers to about 1 millimeter, or near infrared having wavelengths from about 780 nm to about 2500 nm), from a surface of the bedding material toward the user. Such infrared light interactions can be beneficial for sleep recovery, e.g., by interacting with IR light produced by the user's body and reflecting it back toward the user's body during sleep, which in turn can provide beneficial effects such as increasing blood flow and oxygen levels in the user's body, enhancing (e.g., speeding up) recovery time for a user after engaging in intense physical activity (e.g., an athlete), and stimulating other metabolic processes of the user.

Bioceramic materials can be incorporated into any portion of any of the bedding components in any suitable manner such as described herein. The bioceramic materials are ceramic materials that have certain beneficial properties for human body wellness and recovery, including the reflection and/or emission of IR light (near IR and/or far IR) based upon thermal energy generated by the user (e.g., during sleep). By placing bioceramic materials in bedding components, such as at along certain panel surfaces of bedding components and/or within certain bedding components (e.g., within the insulation of the comforter 40), the bioceramic materials can emit and/or reflect IR light toward the user to enhance body recovery (e.g., by possibly increasing blood flow and oxygen levels in the user's body, enhancing/speeding up recovery time for a user after engaging in intense physical activity, and stimulating other metabolic processes of the user).

The following, non-limiting embodiments provide examples of a sleep recovery system including specific bedding components. It is noted that these examples are provided for illustrative purposes only, and that various other embodiments, including different combinations of air vents and/or bioceramic materials for different bedding components, are also possible and encompassed by the present invention.

EXAMPLE 1

Fitted sheet 20 includes printed bioceramic material on the interior surface 27 of the top panel 26, and air vents on the user-facing surface 28 and/or the surface 27 of the top panel 26 (e.g., air vents can extend through the top panel 26 to both surfaces 27, 28 or, alternatively, air vents can be located on one surface 27 or 28 of the top panel 26);

Top sheet 30 includes air vents on one or both surfaces 32, 34 (e.g., air vents extend through the top sheet or, alternatively, only to one surface 32 or 34), and the top sheet 30 further includes printed bioceramic material disposed on a surface 34 of the top sheet (i.e., the surface of the top sheet that opposes the user-facing surface 32);

Comforter 40 includes air vents on one or both surfaces 43, 47 of one or both panels 42 and 44 (e.g., air vents extend through a panel 42, 44 or, alternatively, only at one surface 43, 47 of a panel 42, 44), printed bioceramic material is disposed on at least one interior surface 47 of a panel 42, 44 of the comforter 40, also the comforter also includes bioceramic fibers (e.g., Celliant fibers) within insulation 46 of the comforter (i.e., insulation disposed within the cavity defined between panels 42, 44 of the comforter); and

Each pillow case 50 includes air vents on one or both surfaces 57, 58 of one or both panels 52, 54 (e.g., air vents extend through one or both panels 52, 54 or, alternatively, only to one surface 57, 58 of a panel) and a printed bioceramic material on at least the interior surface 57 of one or both panels 52, 54.

EXAMPLE 2

Fitted sheet 20 includes printed bioceramic material on the interior surface 27 of the top panel 26, and air vents on the user-facing surface 28 and/or the surface 27 of the top panel 26;

Top sheet 30 includes air vents (but no printed bioceramic material) on one or both surfaces 32, 34 of the top sheet;

Comforter 40 includes air vents on one or both surfaces 43, 47 of one or both panels 42 and 44, printed bioceramic material is disposed on at least one interior surface 47 of a panel 42, 44 of the comforter, bioceramic fibers (e.g., CELLIANT fibers) within insulation 46 of the comforter (i.e., insulation disposed within the cavity defined between panels 42, 44 of the comforter); and

Each pillow case 50 includes air vents on one or both surfaces 57, 58 of one or both panels 52, 54, and a printed bioceramic material on at least the interior surface 57 of one or both panels 52, 54.

EXAMPLE 3

Fitted sheet 20 includes air vents (but no printed bioceramic material) on the user-facing surface 28 and/or the surface 27 of the top panel 26;

Top sheet 30 includes air vents (but no printed bioceramic material) on one or both surfaces 32, 34 of the top sheet;

Comforter 40 includes air vents (but no printed bioceramic material) on one or both surfaces 43, 47 of one or both panels 42 and 44, also includes bioceramic fibers (e.g., Celliant fibers) within insulation 46 of the comforter 40; and

Each pillow case 50 includes air vents (but no printed bioceramic material) one or both surfaces 57, 58 of one or both panels 52, 54 of the pillow case.

EXAMPLE 4

Fitted sheet 20 includes printed bioceramic material (but no air vents) on at least the surface 27 of the top panel 26;

Top sheet 30 includes printed bioceramic material (but no air vents) on a surface 34 of the top sheet;

Comforter 40 includes printed bioceramic material (but no air vents) on at least one interior surface 47 of a panel 42, 44 of the comforter 40, also the comforter also includes bioceramic fibers (e.g., Celliant fibers) within insulation 46 of the comforter; and

Each pillow case 50 includes printed bioceramic material (but no air vents) on at least the interior surface 57 of one or both panels 52, 54.

EXAMPLE 5

Fitted sheet 20 includes air vents and bioceramic-containing filaments, fibers or yarns on or along the user-facing surface 28 and/or the surface 27 of the top panel 26;

Top sheet 30 includes air vents and bioceramic-containing filaments, fibers or yarns on or along the user-facing surface 32 and/or the surface 34 of the top sheet;

Comforter 40 includes air vents and bioceramic-containing filaments, fibers or yarns on or along one or both surfaces 43, 47 of one or both panels 42, 44 of the comforter, also includes bioceramic fibers (e.g., Celliant fibers) within insulation 46 of the comforter 40; and

Each pillow case 50 includes air vents and bioceramic-containing filaments, fibers or yarns on or along the user-facing surface 58 and/or the interior surface 57 of the pillow case.

EXAMPLE 6

Fitted sheet 20 includes air vents, printed bioceramic material and bioceramic-containing filaments, fibers or yarns on or along the user-facing surface 28 and/or the surface 27 of the top panel 26;

Top sheet 30 includes air vents, printed bioceramic material and bioceramic-containing filaments, fibers or yarns on or along the user-facing surface 32 and/or the surface 34 of the top sheet;

Comforter 40 includes air vents, printed bioceramic material and bioceramic-containing filaments, fibers or yarns on or along one or both surfaces 43, 47 of one or both panels 42, 44 of the comforter, also includes bioceramic fibers (e.g., Celliant fibers) within insulation 46 of the comforter 40; and

Each pillow case 50 includes air vents, printed bioceramic material and bioceramic-containing filaments, fibers or yarns on or along the user-facing surface 58 and/or the interior surface 57 of the pillow case.

In a further embodiment, the active or functional layer may be configured for thermal management. A comfort or thermal regulation membrane or layer is disposed on a surface of the bedding component (e.g., the surface facing the user). The thermal regulation membrane is effective to alter the temperature regulation and/or moisture management properties of the substrate. Accordingly, the thermal regulation membrane contains one or more system reactive components. By system reactive, it is intended to mean a compound that reacts to environmental conditions within a system. That is, the system reactive materials are selectively engaged in response to conditions of a wearer wearing the article of apparel. In particular, the compound absorbs, directs, and/or mitigates fluid (heat or water) depending on existing system conditions. For example, a component may initiate an endothermic reaction (e.g., when exposed to water). By way of further example, a component may be capable of selectively absorbing and releasing thermal energy (heat). By way of still further example, a component may be capable or conducting and/or directing heat from one location to another location within a system.

In an embodiment, the system reactive components include a cooling agent, a latent heat agent, and/or a heat dissipation agent. The cooling agent is an endothermic cooling agent, i.e., it creates a system that absorbs heat. Specifically, the cooling agent generates an endothermic reaction in aqueous solution, absorbing energy from its surroundings. Accordingly, the cooling agent possesses a negative heat of solution when dissolved in water. By way of example, the endothermic cooling agent possesses a heat of enthalpy in the range −10 Cal/g to −50 Cal/g. In particular, the endothermic cooling agent possesses a heat of enthalpy in the range −20 Cal/g to −40 Cal/g. With this configuration, when the cooling agent is contacted by water (i.e., the sweat of the wearer), the cooling agent is capable of cooling (i.e., lowering the temperature of) the water.

The cooling agent may be a polyol. By way of example, the cooling agent includes one or more of erythritol, lactitol, maltitol, mannitol, sorbitol, and xylitol. In an embodiment, the cooling agent is selected from one or more of sorbitol, xylitol and erythritol. Sorbitol is a hexavalent sugar alcohol and is derived from the catalytic reduction of glucose. Xylitol is produced by catalytic hydrogenation of the pentahydric alcohol xylose. Erythritol is produced from glucose by fermentation with yeast. Crystalline xylitol is preferred. The cooling agent may be present in an amount of about 15 wt. % to about 35 wt. % (e.g., about 25 wt. %).

The latent heat agent is capable of absorbing and releasing thermal energy from a system while maintaining a generally constant temperature. In an embodiment, the latent heat agent is a phase change material (PCM). Phase change materials possess the ability to change state (solid, liquid, or vapor) within a specified temperature range. PCMs absorb heat energy from the environment when exposed to a temperature beyond a threshold value, and release heat to the environment once the temperature falls below the threshold value. For example, when the PCM is a solid-liquid PCM, the material begins as a solid. As the temperature rises, the PCM absorbs heat, storing this energy and becoming liquefied. Conversely, when temperature falls, the PCM releases the stored heat energy and crystallizes or solidifies. The overall temperature of the PCM during the storage and release of heat remains generally constant.

The phase change material should possess good thermal conductivity (enabling it to store or release heat in a short amount of time), a high storage density (enabling it to store a sufficient amount of heat), and the ability to oscillate between solid-liquid phases for a predetermined amount of time. Additionally, the phase change material should melt and solidify at a narrow temperature range to ensure rapid thermal response.

Linear chain hydrocarbons are suitable for use as the phase change materials. Linear chain hydrocarbons having a melting point and crystallization point falling within approximately 10° C. to 40° C. (e.g., 15° C. to 35° C.) and a latent heat of approximately 175 to 250 J/g (e.g., 185 to 240 J/g) may be utilized. In particular, a paraffin linear chain hydrocarbon having 15-20 carbon atoms may be utilized. The melting and crystallization temperatures of paraffin linear chain hydrocarbons having 15-20 carbon atoms fall in the range from 10° C. to 37° C. and 12° C.-30° C., respectively. The phase transition temperature of linear chain hydrocarbons, moreover, is dependent on the number of carbon atoms in the chain. By selecting a chain with a specified number of carbon atoms, a material can be selected such that its phase transition temperature liquefies and solidifies within a specified temperature window. For example, the phase change material may be selected to change phase at a temperature near (e.g., 1° C.-5° C. above or below) the average skin temperature of a user (i.e., a human wearer of the apparel, e.g., 33° C.-34° C.). With this configuration, the phase change material begins to regulate temperature either upon placement of the apparel on the wearer or shortly after the wearer begins physical activity.

In an embodiment, the paraffin is encapsulated in a polymer shell. Encapsulation prevents leakage of the phase change material in its liquid phase, as well as protects the material during processing (e.g., application to the substrate) and during consumer use. The resulting microcapsules may possess a diameter of about 1 to about 500 um. In an embodiment, the paraffin PCM is present in an amount of about 25 wt. % to about 45 wt. % (e.g., about 35 wt. %).

The heat dissipation agent is effective to conduct heat and/or direct heat from one location to another location within the system (e.g., within the membrane 150 and/or substrate 105). In an embodiment, the heat dissipation agent possesses a high heat capacity, which determines how much the temperature of the agent will rise relative to the amount of heat applied. By way of example, the heat dissipation agent is a silicate mineral such as jade, e.g., nephrite, jadeite, or combinations thereof. The heat dissipation material may be present in an amount (dry formulation) of about 30 wt. % to about 50 wt. % (e.g., about 40 wt. %).

The system reactive components are present with respect to each other in a ratio of approximately 1:1 to 1:2. By way of example, the ratio of temperature reactive components—cooling agent, latent heat agent, and heat dissipation agent—may be approximately 1:2:2, respectively. As indicated above, in system reactive component mixture, the cooling agent is present in an amount of from 15 wt. % to 35 wt. %; the latent heat agent is present in an amount of from 25 wt. % to 45 wt. %. Similarly, the heat dissipation agent is present in an amount of from 25 wt. % to 45 wt. %.

In addition to the temperature reactive components, the thermal regulation membrane 150 further includes a binder effective to disperse the temperature reactive components and/or to adhere the temperature reactive components to the substrate 105 (e.g., to the yarns/fibers forming the substrate). The binder may be an elastomeric material possessing good elongation and tensile strength properties. Elastomeric materials typically have chains with high flexibility and low intermolecular interactions and either physical or chemical crosslinks to prevent flow of chains past one another when a material is stressed. In an embodiment, polyurethane (e.g., thermoplastic polyurethane such as polyester-based polyurethane) is utilized as the binder. In other embodiments, block copolymers with hard and soft segments may be utilized. For example, styrenic block copolymers such as a styrene-ethylene/butylene-styrene (SEBS) block copolymer may be utilized.

The thermal regulation membrane may be applied in a manner similar to the bioceramic composition (e.g., printing).

Thus, the sleep recovery system can include bedding components with a variety of different combinations of sleep recovery features (e.g., different combinations of air vents and bioceramic materials, and thermal regulation materials), where the sleep recovery features can be varied to modify the sleep recovery effects imparted to the user for a particular application.

While the invention has been described in detail and with reference to specific embodiments thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof. For example, the bedding components can include any suitable configurations, including any one or more fabric panels with one or more surfaces (e.g., user-facing surfaces and/or underside surfaces or surfaces that oppose the user-facing surfaces) that include one or more sleep recovery features as described herein. Any suitable types of patterns can be utilized for printing of a ceramic material on a surface of a fabric panel so as to facilitate enhanced recovery benefits for the user, where the ceramic material can be of any suitable type(s) that facilitate IR light reflectivity and/or IR light emissivity. Further, the bioceramic material can be integrated within a fiber, filament and/or yarn in combination with any one or more other suitable polymer components, where such fiber, filament and/or yarn can be integrated in any suitable manner within the bedding component. Any combinations of air vents and/or ceramic material applied to one or more surfaces of a bedding component can be configured for a particular user application.

The air vents can be formed in bedding components at any selected locations and/or along any selected outer surfaces of the bedding components. In particular, each of the bedding components, i.e., the fitted sheet 20, the top sheet 30, the comforter 40 and the pillow cases 50, can include at least one surface (e.g., the user-facing surface, or sleep recovery surface as previously described herein) that includes air vents defined by the engineered apertures. In some embodiments, only one surface (e.g., the user-facing surface) of one or more bedding components includes a sleep recovery/user-facing surface that includes air vents. In other embodiments, both surfaces (e.g., the user-facing surface and the surface that opposes the user-facing surface) of one or more bedding components includes air vents.

In further embodiments, one or more bedding components can include air vents located in a selected pattern or array along the entire sleep recovery surface of the bedding component or, alternatively, along only one or more selected locations of the sleep recovery surface of the bedding component. For example, for the top sheet 30, the bottom or user-facing surface 32 (i.e., the sleep recovery surface) can include air vents (e.g., air vents comprising engineered apertures 535 of the type depicted for the textile structure 500 of FIG. 5) disposed in an array or pattern (e.g., a grid-like array) along the entire surface 32 or, alternatively, along selected portions of the surface 32. The air vents can extend through the fabric structure of the top sheet 30 such that both the bottom/user-facing surface 32 and the upper/opposing surface 34 include air vents. Alternatively, the air vents may only extend partially through the fabric structure of the top sheet 30 such that only one surface (e.g., user-facing surface 32) includes the air vents. The other bedding components can include similar air vents along their sleep recovery surfaces. For example, the fitted sheet 20 can include air vents disposed along one or both of the surfaces 27, 28 of the top panel 26 and/or along one or more surfaces of any of the other side panels 22, 24. Similarly, the comforter 40 can include air vents disposed along outer surfaces (e.g., user-facing surface 43) and/or interior surfaces 47 of the panels 42, 44, while each pillow case 50 can also include air vents disposed along one or more exterior surfaces 58 and/or one or more interior surfaces 57 of the panels 52, 54.

As previously noted, any combination of bedding components can include one or more sleep recovery surfaces including air vents and/or bioceramic material disposed over selected surface portions (e.g., over the entire area or only selected are portions of a sleep recovery surface) as well as sleep recovery elements integrated in any suitable manner with a fabric structure of a bedding component (e.g., as bioceramic fibers combined with insulation fibers or other insulation material within a fabric structure of a bedding component, such as within a comforter as described herein). For example, a bedding component can include a fabric panel with a first surface and a second surface that opposes the first surface. The fabric panel can include air vents and a bioceramic material printed layer disposed on portions of one or both of the first and second surfaces such that the bioceramic material printed layer and air vents are disposed together on the first surface and/or the second surface. In another example, the fabric panel can be configured such that air vents and bioceramic material printed layer are not disposed on the same surface. Such embodiments include a fabric panel in which air vents are disposed on the first surface (e.g., a surface that, in use, faces the user) and a bioceramic material printed layer disposed on the second surface (e.g., a surface that, in use, faces away from the user). Further still, embodiments can include a fabric panel in which air vents are disposed on both first and second surfaces (e.g., the air vents extend through the fabric panel) but the bioceramic material printed layer is only on one of the first and second surfaces. Even further, embodiments can include a fabric panel in which the bioceramic material printed layer is disposed on both first and second surfaces, but the air vents are only disposed on one of the first and second surfaces.

The apertures 335, 340 are designed so as to extend through the thickness of the fabric material. In alternative embodiments, the air vents/engineered apertures can be designed to not extend through the fabric material but instead provide a reduced thickness in the fabric material at the air vent locations, where the air vents can extend to one surface of the fabric material but do not extend through the fabric material to an opposing surface of the fabric material.

It is further intended that the present invention covers the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents. It is to be understood that terms such as “top,” “bottom,” “front,” “rear,” “side,” “height,” “length,” “width,” “upper,” “lower,” “interior,” “exterior,” “medial,” “lateral,” and the like as may be used herein, merely describe points of reference and do not limit the present invention to any particular orientation or configuration.

Claims

1. A method of forming a bedding component with apertures, the method comprising:

obtaining a woven structure comprising a plurality of warp yarns and a plurality of weft yarns;
forming a warp channel in the woven structure by dissolving a warp yarn of the plurality of warp yarns; and
forming a weft channel in the woven structure by dissolving a weft yarn of the plurality of weft yarns.

2. The method of claim 1, wherein:

the woven structure comprises: a first edge and an opposed second edge, and a third edge and an opposed fourth edge; the warp yarn extends from the first edge to the second edge of the woven textile; the weft yarn extends from the third edge to the fourth edge of the woven textile; the warp yarn overlaps the weft yarn at an intersection; and
forming the warp and weft channels further forms engineered apertures in the woven structure.

3. The method of claim 2, wherein:

the engineered apertures include: a first engineered aperture possessing a first set of dimensions, a second engineered aperture possessing a second set of dimensions; and
the first set of dimensions differ from the second set of dimensions.

4. The method of claim 3, wherein:

the woven structure defines a surface;
the method further comprises printing a composition onto the surface of the woven structure, the printing composition including particles operable to emit infrared light; and
the printed composition is printed in a discontinuous pattern to form printed areas and non-printed areas on the surface of the woven structure.

5. The method of claim 4, wherein the particles operable to emit infrared light comprise silica particles.

6. The method of claim 1, wherein the bedding component comprises a fitted sheet, the fitted sheet including a body comprising the woven structure, a side panel that extends along a perimeter of the body, and an elastic member coupled to the side panel.

7. The method of claim 6, wherein the bedding component comprises two layers that define a pocket between an internal surface of each of the two layers, at least one of the two layers comprises the woven textile structure, and the ink composition is printed on an internal surface of at least one of the two layers.

8. A method of forming a bedding component, the method comprising:

obtaining a woven textile including a plurality of weft yarns and a plurality of warp yarns, wherein:
the plurality of weft yarns includes a dissolvable weft yarn that is dissolvable in a solvent and an inert weft yarn that does not dissolve in the solvent,
the plurality of warp yarns includes a dissolvable warp yarn that is dissolvable in the solvent and an inert warp yarn that does not dissolve in the solvent, and
the dissolvable weft yarn overlaps the dissolvable warp yarn;
exposing the woven textile structure to the solvent to dissolve the dissolvable warp yarn and the dissolvable weft yarn, thereby forming an aperture in the woven textile; and
forming a bedding component with the woven textile.

9. The method of claim 8, wherein the woven textile includes a plurality of dissolvable weft yarns and a plurality of dissolvable warp yarns, the method further comprising exposing the woven textile structure to the solvent to dissolve the plurality of dissolvable weft yarns and the plurality of dissolvable warp yarns.

10. The method of claim 9, wherein:

the woven textile further includes a plurality of inert weft yarns and a plurality of inert warp yarns; and
a ratio of inert weft yarns and inert warp yarns to dissolvable weft yarns and dissolvable warp yarns in the woven textile is from approximately 10:1 to approximately 7:3.

11. The method of claim 10, wherein:

the plurality of dissolvable weft yarns and the plurality of dissolvable warp yarns are formed of a polyester dissolvable in water;
the plurality of inert weft yarns and the plurality of inert warp yarns are formed of a polyester that is not dissolvable in water; and
the method further comprises exposing the woven textile to water.

12. The method of claim 9, wherein, after exposing the woven textile to the solvent, the woven textile includes:

a first area comprising inert warp yarns and inert weft yarns;
a second area including only inert warp yarns;
a third area including only inert weft yarns; and
a fourth area including no yarns.

13. The method of claim 8, wherein obtaining the woven textile comprises weaving the woven textile by interlacing a plurality of yarns such that two or more yarns of the plurality of yarns are oriented generally orthogonally to each other.

14. A bedding component for a mattress, the bedding component comprising a woven textile structure including a plurality of weft yarns and a plurality of warp yarns, wherein:

the plurality of weft yarns includes a dissolvable yarn that is dissolvable in a solvent and an inert yarn that does not dissolve in the solvent;
the plurality of warp yarns includes a dissolvable yarn that is dissolvable in the solvent and an inert yarn that does not dissolve in the solvent; and
the dissolvable weft yarn intersects with the dissolvable warp yarn.

15. The bedding component of claim 14, further comprising a discontinuous print layer applied to the woven textile structure, the print layer including printed segments and non-printed segments.

16. The bedding component of claim 14, wherein the print layer comprises ceramic material and a binder, and the ceramic material comprises silica.

17. The bedding component of claim 14, wherein each non-printed segment forms a hinge that permits flexure of the woven textile structure along the non-printed segments, first printed segments connect to form patterns of cells, second printed segments extend between and connect two or more first printed segments of adjacent cells, and the first printed segments are larger in width in relation to the second printed segments.

18. The bedding component of claim 14, wherein the bedding component comprises a fitted sheet including a side panel portion bordering the body portion and extending along a perimeter of the body, and an elastic member coupled to the side panel.

19. The bedding component of claim 14, wherein the bedding component comprises two layers that define a pocket between an internal surface of each of the two layers, at least one of the two layers comprises the woven textile structure, and the print layer is provided on an internal surface of at least one of the two layers.

20. The bedding component of claim 14, wherein the woven textile structure includes yarns comprising a ceramic material incorporated within the yarns.

21. The bedding component of claim 14, wherein the plurality of weft yarns includes:

a first dissolvable yarn adjacent a second dissolvable yarn; and
an inert yarn adjacent the second dissolvable yarn on a side opposite the first dissolvable yarn.
Patent History
Publication number: 20220218115
Type: Application
Filed: Mar 29, 2022
Publication Date: Jul 14, 2022
Inventor: Kyle Blakely (Baltimore, MD)
Application Number: 17/707,147
Classifications
International Classification: A47C 21/04 (20060101); D03D 15/47 (20060101); A47C 31/10 (20060101); A47G 9/02 (20060101); D03D 15/68 (20060101);