FLAT WOVEN FABRIC WITH DURABLE DROP AREA, AND RELATED PROCESSES

Abstract

Woven sheets, more particularly to fitted sheets having a woven fabric top cover to cover the top surface of a mattress, and drop area for fitting around all the four sides and corners of the mattress. The woven fabric for the top cover is consisting of flat fabric of natural fiber and/or natural fiber blends and/or natural and manmade fiber blends. The woven fabric for the drop area is consisting of flat fabric of manmade fiber and/or manmade fiber blends. The drop area is stitched around the top cover. The stitched woven sheet is sustainable, economic, quick dry, durable and suitable for bedding applications.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit of and priority to Indian Patent Application No. 20222103921, filed on Jul. 7, 2022, the entire contents of which are incorporated by reference herein in its entirety.

TECHNICAL FIELD

The present disclosure relates to woven sheets, more particularly to fitted sheets having a woven fabric top cover to cover the top surface of a mattress and drop area for fitting around all the four sides and corners of the mattress.

BACKGROUND

The textile industry is a major employment provider and revenue generator globally. Recently, the textile industry has achieved several technological advancements, and has adopted to environmental-safe operational procedures. Moreover, the textile industry is further evolving with improved durability for fabrics having global acceptability.

Conventional fitted sheets have a woven fabric top cover to cover the top surface of a mattress and drop area for fitting around all the four sides and corners of the mattress. These conventional woven sheets are normally made of either natural fiber or natural fiber blends or manmade fibers or manmade fiber blends or any combination thereof. However the comfort and the elegant look in the woven sheets are much higher for the sheets made with 100% natural fiber or natural fiber blends as compared to sheets manufactured using manmade fibers. Hence customers and users of the sheets preferred natural fabric woven sheets.

There are various patented fitted sheets such as U.S. Pat. No. 7,398,570 which discloses a fitted mattress cover in which a top panel of material for fitting in overlaying relationship to the top surface of a mattress and a peripheral skirt depending from the periphery of the top panel for fitting in overlaying relationship to the sides and ends of the mattress. The peripheral skirt comprises: a pair of extension sidewall panels attached to the top panel, said sidewall panels being sized and configured to overlie substantially the entire sides of the mattress; a pair of extension end panels attached to the top panel, at least one of said end extension end panels being sized and configured to overlie substantially only an upper partial portion of the end walls of the mattress; and at least one stretch end panel sized and configured to overlie substantially only a lower partial portion of a respective end wall below the upper partial portion. The stretch end panel is formed of a stretchable material stretchable in at least a longitudinal direction thereof so as to generate at least partial recovery force. The stretch end panel is attached along its upper edge thereof to a corresponding peripheral edge of a corresponding one of the extension end panels and being attached at its ends, either directly or indirectly, to corresponding end edges of the sidewall panels. Upon installation of the mattress covering, the at least partial recovery force pulls on said end edges of the sidewall panels.

U.S. Patent Application Pub. No. 20050193490 discloses a mattress pad having a central rectangular panel comprising a plurality of layers including an upper textile layer, a lower textile layer, and a batting layer quilted to at least one of the upper and lower textile layers. It includes side panels depending from said central panel and comprising a single layer of a textile fabric. End panels are defined by extensions of the central panel. The side panels being joined to the end panels by seams extending in a transverse direction in relation to said rectangular central panel. To fit the woven sheet over the mattress, the drop area of the sheets inserted under the mattress and above a hard surface such as wooden or metal bed or the floor as the case may be. Due to this exercise to fit the woven sheet, the drop area experienced more wear and tear as compared to the top cover. The wear and tear are likely to rupture of the drop area. The durability of natural fiber sheets are also quite low as compared to manmade fiber sheets. Moreover these sheets would consume more energy to dry due to higher moisture regain of natural fiber. The above-mentioned patent does not address these problems.

Recent advancements in manufacturing of durable woven sheets involves high thread count sheets. However conventional high thread count sheets require more raw material and more manufacturing requirements such as electricity, machines and man power which result into the higher cost. Naturally the cost of the high thread count woven sheet will also increase. Furthermore, conventional natural fabrics, which may be low or high thread count woven sheets, will have longer drying times. This will result in further increase in energy consumption as required for the sheets made of natural fibers.

Therefore, in light of the foregoing discussion, there exists a real need to overcome the aforementioned drawbacks associated with the conventional woven sheet. The present invention has a particularly advantageous application to sustainable, economic, quick dry and durable fitted bed sheets.

SUMMARY

An embodiment of the disclosure is a bedding article that includes a combination of two flat fabrics out of which one includes a top cover and the other includes a drop area. The bedding article as described herein may include sheets, mattress covers or bed covers, e.g., mattress pads used underneath sheets to protect the mattress and/or provide a softer surface, to provide a smooth feel and elegant appearance to a mattress.

A top cover of the bedding article includes a flat woven fabric (referred to as a first flat woven fabric). The first flat woven fabric includes a warp component including warp yarns and a weft component including weft yarns interwoven with the warp yarns to define the woven fabric. At least one of a) the warp component, and b) the weft component includes a plurality of the staple spun yarns. Each staple spun yarn has a length and a plurality of single staple spun yarns or multi-ply staple spun yarns twisted together.

The drop area of the bedding article includes a second flat woven fabric. The second flat woven fabric includes a warp component including warp yarns and a weft component including weft yarns interwoven with the warp yarns to define the woven fabric. At least one of the warp component include a plurality of the staple spun yarns, and the weft component include a staple spun yarn or filament yarn. Each staple spun yarn has a length and a plurality of single staple spun yarns or multi-ply staple spun yarns twisted together. A filament yarn is made of one or more continuous filament strands with each component filament running the whole length of the yarn. Monofilament yarns are the yarns composed of one single filament, and more than one filament are multifilament yarns.

Another embodiment of the disclosure is a process for manufacturing a bedding article. The process includes cutting and sewing the drop area and top cover into a flat bedding article. In one example, the cutting step includes cutting top cover and drop area. In another example, the sewing step includes sewing top cover and drop area into a flat fabric sheet.

BRIEF DESCRIPTION OF DRAWINGS

The foregoing summary, as well as the following detailed description of illustrative embodiments of the present application, will be better understood when read in conjunction with the appended drawings. For the purposes of illustrating the present application, there is shown in the drawing's illustrative embodiments of the disclosure. It should be understood, however, that the application is not limited to the precise arrangements and instrumentalities shown. In the drawings:

FIG. 1 is an isometric view of a bedding article configured as a fitted sheet according to an embodiment of the present disclosure;

FIG. 2 is the bottom view of the bedding article shown in FIG. 1, with four elastic bands stitched at four corners in a tangential way at the bottom end of the drop area;

FIG. 3 is an isometric view of another embodiment of the bedding article whereby the drop area is stitched around the top cover along with elastic band;

FIG. 4 is an isometric view of another embodiment of the bedding article where the drop area is stitched with a box pleating effect;

FIG. 5 depicts the bottom view of FIG. 4;

FIG. 6 is an isometric view of another embodiment of the bedding article showing the drop area stitched around the top cover along with elastic band and the drop area including a box pleating effect;

FIG. 7 is an isometric view of another embodiment of the bedding article showing top cover along with drop area stitched around with a self-piping;

FIG. 8 is an isometric view of another embodiment of the bedding article showing top cover along with drop area stitched around with a contrast piping and with the bottom end of the drop area including an elastic band;

FIG. 9 is an isometric view of another embodiment of the bedding article showing the drop area stitched around the top cover along with a contrast flat and cord piping;

FIG. 10 is an isometric view of another embodiment of the bedding article showing the drop area stitched around the top cover with an elastic band and the four corners of the drop area including T shaped elastic bands;

FIG. 11 depicts the bottom view of FIG. 10;

FIG. 12 is an isometric view of another embodiment of the bedding article showing the drop area is further stitched with hook and loop fasteners;

FIG. 13 is an isometric view of another embodiment of the bedding article showing the drop area including a zipper; and

FIG. 14 is an isometric view of another embodiment of the bedding article showing the drop area including a snap fastener.

DESCRIPTION

Embodiments of the present disclosure include bedding articles 100 with unique flat fabric structures, which include fiber type and its blends, yarns, fabrics, and related articles that are highly absorbent, soft, comfortable, durable, economical and adapted for home textile applications. The flat fabric structures may be suitable for bedding articles that include the woven fabric sheets, mattress covers and bed covers, e.g., mattress pads used underneath sheets to protect the mattress and/or provide a softer surface, to provide a smooth feel and elegant appearance to a mattress. Also described herein are processes and devices used to manufacture flat fabric. As used herein, the term fitted sheet is used in its generic sense to include but not limited to sheets, bed sheets, mattress covers or bed covers, to provide a smooth, comfortable feel and elegant appearance to a mattress. The present invention has particularly advantageous application to sustainable, economic, quick dry and durable fitted bed sheets.

As shown in FIGS. 1-2, embodiments of the present disclosure include a bedding article 100. The bedding article 100 include a top cover 102 formed from a first flat woven fabric, and a drop area 104 from a second flat woven fabric. The drop area 104 is attached to the top cover 102 via stitching and the like. The first flat woven fabric has a warp component including warp yarns and a weft component including weft yarns interwoven with the warp yarns to define the flat woven fabric. As shown, at least one of a) the warp component and b) the weft component comprise a plurality of the staple spun yarns. The second flat woven fabric is different from the first flat woven fabric. The second flat woven fabric has a warp component including warp yarns and a weft component including weft yarns interwoven with the warp yarns to define the flat woven fabric. In the second flat woven fabric, at least one of a) the warp component and b) the weft component includes staple spun yarns or filament yarns each made of man-made fibers. The different yarns structures and fabric structures for the first and second flat woven fabrics are described further below.

In FIGS. 1-14, there is illustrated different configurations for the bedding article 100. While different part numbers are used to illustrate different components of different embodiment, each embodiment is a bedding article including a top cover and drop area. The same reference numbers are used for features that are common to all embodiments.

Turning to FIG. 2, which depicts the bottom view of the bedding article 100 having four elastic bands 206 stitched at four corners in a tangential way at the bottom end of the drop area 104.

In FIG. 3, the drop area 304 is stitched around the top cover 302 along with elastic band 306. As shown, the elastic band 306 extends around an entirety of the perimeter of the top cover. FIG. 4 depicts the isometric view of the bedding article with top cover 402 and drop area 404 having a box pleating effect 408 along each side of the article 100. FIG. 5 shows a bottom view of bedding article shown in FIG. 4 with four elastic bands 506 located at corners of the bottom end of the drop area 404.

FIG. 6 depicts another version of bedding article 100 with a top cover 602 and drop area 604 stitched around the top cover 602 along with elastic band 606. The drop area 604 is stitched with a box pleating effect 608.

FIG. 7 is another version of the bedding article 100 with a top cover 702 along with drop area 704 stitched around the perimeter with a self-piping 710. The bottom end of the drop area 704 is further stitched with an elastic band 706 all around the entirety of the bottom end of the article 100.

FIG. 8 is another version of the bedding article 100 that includes a top cover 802 along with drop area 804 stitched around the perimeter of the top cover 802 with a contrast piping 812. The bottom end of the drop area 804 is further stitched with an elastic band 806 all around the entirety of the bottom end.

FIG. 9 is another version of the bedding article 100 with a top cover 902, a drop area 904 stitched around the perimeter of the top cover 902 along with a contrast flat and cord piping 914. The bottom end of the drop area 904 is further stitched with an elastic band 906 all around.

FIGS. 10 and 11 show yet another version of the bedding article 100 with a top cover 1002 and a drop area 1004 stitched around the top cover 1002. The bottom end of the drop area 1004 is further stitched with the elastic band 1006 all the way around the bottom end. The four corners of the drop area are further stitched with T shaped elastic bands 1016.

FIGS. 12-14 illustrate different variations for securing the bedding article 100 in place. In FIG. 12, the article 100 includes a top cover 1202 and a drop area 1204 stitched around the top cover 1202. The bottom end of the drop area is further stitched with the with a hook and loop fastener system 1218, 1220. In one example, the hook and loop fasteners are Velcro bands. In one example, one corner of the drop area 1204 is stitched with a hook portion 1218 and an adjoining corner is stitched with a loop portion 1220.

FIG. 13 shows a bedding article 100 with a top cover 1302 and a drop area 1304 stitched around the top cover 1302. The bottom end of the drop area 1304 is further stitched with the zipper system 1322. The one corner of the drop area 1304 is stitched with one side of the zipper and the next adjoining corner is stitched with the extendible other side of the zipper and a runner is used to complete the zipper system 1322.

FIG. 14 shows an article 100 with a top cover 1402 and a drop area 1404 stitched around the top cover 1402. The bottom end of the drop area 1404 is further stitched with the snap fastener 1424.

Each bedding article shown in FIGS. 1-14 and described above is made from the first flat woven fabric for the top cover and a second flat woven fabric for the drop area. In addition, each component shown in FIGS. 1-11, e.g. the elastic bands, piping, pleats, T-shaped elastic bands, may be used in combination with the hook and loop fasteners, zipper, or snap fasteners shown in FIGS. 12-14. Furthermore each component shown in FIGS. 1-11, e.g. the elastic bands, piping, pleats, T-shaped elastic bands, may be used in combination with each other as needed.

The yarn configurations described in the present disclosure can have several different structures. In one embodiment, the yarn configuration is a staple spun yarn formed from single end and/or multi ply yarns. Each staple spun yarn has a length and a plurality of single-ply staple spun yarns or multi-ply staple spun yarns twisted together. In another embodiment, the staple yarn could be made of 100% natural fiber. In yet another embodiment, the staple yarn could be made of 100% natural fiber blends. In another embodiment, the staple yarn could be made of 100% manmade staple fiber. In yet another embodiment, the staple yarn could be made of 100% manmade staple fiber blends. In another embodiment, the staple yarn could be made of natural fiber or natural fiber blends and manmade staple fibers or manmade staple fibers blends or any combination thereof. In another embodiment, the yarn configuration is a filament yarn. A filament yarn is made of one or more continuous filament strands with each component filament running the whole length of the yarn. Monofilament yarns are the yarns composed of one single filament, and more than one filaments are multifilament yarns.

The flat fabric as described herein may be defined by a number of different woven structures or woven design repeats. Depending on the particular design, woven design repeats may repeat along weft direction and warp direction; or both weft direction and warp directions. However, the design of the woven fabric is not limited to any particular weave structure. For example, the woven fabric can have a number of exemplary woven structures including, but are not limited to: plain weaves; basket weaves, rib weaves (e.g. 2×1 rib weave; 2×2 rib weave; or 3×1 rib weave); twill weaves; oxford weaves; percale weaves, satin weaves (e.g. satin dobby base, satin stripe satin 5/1, satin 4/1 satin; 4/1 satin base strip; 4/1 stain swiss dot; 4/1 down jacquard; 5/1 satins), or sateen weaves. In one example, the woven fabric is a plain weave. In another example, the woven fabric is a basket weave. In another example, the woven fabric is a rib weave. In another example, the woven fabric is a twill. In another example, the woven fabric is an oxford weave. In another example, the woven fabric is a sateen weave. In another example, the woven fabric is any other possible weave structure. In another example, the woven fabric is a satin weave. Furthermore, a number of exemplary satin constructions are possible. For instance, in one satin weave example, the woven fabric is a 4/1 satin. In another example, the woven fabric is a 4/1 satin dobby diamond weave. In another example, the woven fabric is a 4/1 satin dobby stripe. In yet another example, the woven fabric is a 4/1 satin jacquard weave. In another example, the woven fabric is a 5/1 satin. In still another example, the woven fabric may be a 6/1 satin. In another example, the woven fabric is a 7/1 satin. In yet another example, the woven fabric is a 8/1 satin. In another example, the woven fabric is a 9/1 satin. And in another example, the woven fabric is a 10/1 satin.

The present disclosure can utilize co-insertion techniques to insert multiple weft yarns along a weft insertion path in a single weft insertion event during weaving, as will be further detailed below. A person of skill in the art will appreciate that the weft insertion path varies from one woven design to another woven design. By inserting groups of multiple weft yarns into the shed during a weft insertion event, it is possible to attain increased weft (or pick or fill) densities and therefore higher thread counts. Thus, the woven fabric as described herein may be constructed to have higher weft yarn densities than what is otherwise possible, and thus higher thread counts, yet the woven fabric exhibits desirable fabric quality, softness, hand, and drape suitable for bedding applications. The thread count of the woven fabrics made in accordance with present disclosure are typically greater than about 100 and can be as high as about 2000 (or even higher). The thread count as used herein is the total number of yarns in square inch of fabric. The thread count in this context is based on total number of yarn ends. In other words, plied yarns are considered one yarn for the purpose of determining thread count.

The present disclosure can utilize co-insertion techniques to insert multiple weft yarn along a weft insertion path in a single weft insertion event during weaving, as will be further detailed below. A “co-insertion” technique is where multiple pick or weft yarns are inserted into the warp shed at one time during weaving. In co-insertion, two pick yarns supplied from two different yarn packages are inserted at one time through the shed during weaving. Co-insertion may also include inserting three or more yarns supplied from the three or more different yarn packages into the shed during weaving. In one example, the woven fabric has between one (1) weft yarn and seven (7) weft yarns inserted during a single insertion event, i.e. along the weft insertion path.

The warp yarns and weft yarns are arranged to achieve desired warp and weft end densities, respectively, and thus desired thread count, for bedding applications. In accordance with an embodiment of the present disclosure, the woven fabric has a warp end density between about 50 warp ends per inch and about 550 warp ends per inch. In one example, the warp end density is between about 50 and 150 warp ends per inch. In another example, the warp end density is between about 150 and 250 warp ends per inch. In another example, the warp end density is between about 250 and 350 warp ends per inch. In another example, the warp end density is between about 350 and 450 warp ends per inch. In another example, the warp end density is between about 450 and 550 warp ends per inch. Furthermore, the weft yarns are arranged to define a weft end density between about 50 weft yarns per inch and about 1500 weft yarns per inch (or more). In one example, the weft yarn density is between about 100 and about 1500 weft yarns per inch. In one example, the weft yarn density is between about 100 and about 300 weft yarns per inch. In another example, the weft yarn density is between about 300 and about 500 weft yarns per inch. In another example, the weft yarn density is between about 500 and about 700 weft yarns per inch. In another example, the weft yarn density is between about 700 and about 900 weft yarns per inch. In another example, the weft yarn density is between about 900 and about 1100 weft yarns per inch. In another example, the weft yarn density is between about 1100 and about 1300 weft yarns per inch. In another example, the weft yarn density is between about 1300 and about 1500 weft yarns per inch. The weft yarn density has used herein refers to the total number of separate weft yarns along a length of the woven fabric. For example, a weft yarn density of about 50 picks per inch refers the 50 total weft yarns per inch of woven fabric. If the weft yarn groups are inserted during a single weft insertion event and each group includes three (3) weft yarns, then there would be about 16 total weft yarn groups per inch of fabric and 48 picks per inch.

The yarns can have a range of counts for the different fibers and woven constructions as described herein. The yarn count as used in this paragraph refers to the yarn count for each single end yarn and the yarn count of the multi-ply yarn. The yarn count can range between about 8 Ne (664 denier) to about 140 Ne (37.9 denier). In one example, the yarns can have a count in a range between about 8 Ne (664 denier). In one example, the yarns can have a count in a range between about 20 Ne (266 denier). In one example, the yarns can have a count in a range between about Ne (177 denier). In one example, the yarns can have count in a range between about 40 Ne (133 denier). In another example, the yarns have a count of about 60 Ne (88.6 denier). In another example, the yarns have a count of about 70 Ne (75.9 denier). In another example, the yarns have a count of about 80 Ne (66.4 denier). In another example, the yarns have a count of about 100 Ne (53.1 denier). In another example, the yarns have a count of about 120 Ne (44.3 denier). For flat woven fabrics, the warp yarn counts may range from 20 Ne (266 denier) to about 100 Ne (53.1 denier). The weft yarn counts may range from 20 Ne (266 denier) to about 140 Ne (37.9 denier).

The flat fabric can use different yarn constructions in the warp and weft components. In one example, the warp yarns are typical staple spun yarns (cotton or any fiber blends natural and manmade fibers or 100% manmade fibers) and the weft yarns include single ply or multi-ply staple spun yarns of any fiber blends natural and manmade fibers or 100% manmade fibers. In one example, the warp yarns are typical continuous filament yarns and the weft yarns are single ply yarns or multi-ply staple spun yarns. In another example, the weft yarns are typical staple spun yarns and the warp yarns are single ply yarns or multi-ply staple spun yarns. In one example, the weft yarns are typical continuous filament yarns and the warp yarns are single ply yarns or a multi-ply staple spun yarns. In one preferred embodiment, the warp yarns are typical staple spun yarns and the weft yarns include single ply or multi-ply staple spun yarns. In one preferred embodiment, the warp yarns are typical staple spun yarns and the weft yarns include filament yarn.

The staple fibers may be cotton fiber. Alternatively, for example, in place of cotton, may contain viscose fiber, modal fiber, kapok fiber, raime fiber, hemp fiber, nettle fiber, silk fiber, linen fiber, bamboo fiber, acrylic fiber, polyethylene terephthalate (PET) fiber, polyamide fiber, or blends of fibers or a bi-component fiber, charcoal fiber, PLA fiber. Fiber blends, for example, may include, but are not limited to: cotton and viscose fiber blends; cotton and modal fiber blends; cotton and silk fiber blends; cotton and modal fiber blends, cotton and linen fiber blends; cotton and bamboo fiber blends; cotton and acrylic fiber blends; cotton and PET fiber blends; cotton and polyamide fiber blends; viscose and modal fiber blends; viscose and silk fiber blends; viscose and modal fiber blends, viscose and linen fiber blends; viscose and bamboo fiber blends; viscose and acrylic fiber blends; viscose and PET fiber blends; viscose and polyamide fiber blends; PET and viscose fiber blends; PET and modal fiber blends; PET and silk fiber blends; PET and modal fibers, PET and linen fiber blends; PET and bamboo fiber blends; PET and acrylic fiber blends; and PET and polyamide fiber blends. Or any other possible combinations. The PET fiber as described in the current disclosure may result from PET chips. In one example, the PET chips may be PET could be dull. In another example, the PET chips may be PET could be semi dull. In another example, the PET chips may be PET could be bright. In another example, the PET chips may be PET could be full bright.

The PET fiber as described in the current disclosure may have circular cross-section (CCS). Alternately, for example, in place of circular cross-section fiber of any non-circular cross-section (NCCS) could be used. In one example, the cross-section could be oval shape. In another example cross-section could be tri-lobal. In another example, the cross-section could be quadrilobe shape. In another example, the cross-section could be pentalobal. In another example, the cross-section could be octalobal. In another example, the cross-section could be multilobal. In another example, the cross-section could be delta. In another example, the cross-section could be cross.

In one preferred embodiment, top area is a flat fabric manufactured using typical staple spun yarns (cotton or any fiber blends natural fibers) and drop area is a flat fabric manufactured using mono filament or multi filament yarns or staple spun yarns of any fiber blends of manmade fibers. In order to achieve similar look and feel to the top area, the non-circular cross-section (NCCS) man-made fibers may be used in the second flat woven fabric, used for the drop area. In one example, the NCCS man-made fibers may be PET fibers. More specifically use of quadrilobe cross section PET fiber may be used as the manmade fibers in the drop area. The PET filament yarn count may range from 10 denier to about 300 denier. In an embodiment, the PET filament yarn count range is 10 denier to 30 denier. Yet another embodiment, the PET filament yarn count range is 30 denier to 75 denier. Yet another embodiment, the PET filament yarn count range is 75 denier to 150 denier. Yet another embodiment, the PET filament yarn count range is 150 denier to 300 denier.

As a first step, yarn formation of natural fibers (or cotton fibers) are subject to an opening step in a blow room. In the blow room, the cotton fibers are processed with a bale plucker, opener, multi-mixer, beater and a dustex machine. After opening, the fibers are carded on card machines to deliver card slivers. The sliver from carding is then processed through a breaker drawing step to draw out the slivers. In one example of the breaker drawing step, the number of doublings at the feed end can be 6 and the hank delivered is maintained at about 0.10 to 0.13. In case of blended slivers, each component is separately processed through carding and the individual carded slivers are subsequently blended together on draw frames. From breaker drawing, the slivers can follow one of two processing steps: a lapping step or fed directly roving step.

In instances where combing is needed, processing proceeds from the breaker drawing to the lapping step. As should be appreciated, combing is used to remove short fibers during cotton processing. In the lapping step, a unilap machine converts doublings into a lap of fibers. The lap is processed in a combing step using a comber. The combed cotton sliver is then passed through another finisher drawing step to obtain sliver which can be used as input of roving frame. In one example, the finisher draw frame has a feed hank in the range of 0.10 to 0.13 and a delivery hank in the range of 0.65 to 2.5 and at speeds up to about 400 meters per minute.

Referring back to step, in certain instances, the slivers produced at breaker drawing step are fed to finisher drawing and then directly to the roving step, further explained below.

As a next step, the sliver is fed to the speed frame which includes an inlet condenser, a middle condenser, a main feed condenser, multiple sets of drafting rollers, and a flyer. Typically, slivers are processed through an inlet zone, back drafting zone, middle drafting zone, and a forward drafting zone. The condensers are disposed along these different zones at or near their respective drafting rollers. The cotton sliver follows a normal path from the back to the front of the speed frame through at least the main feed condenser. The twisting and winding on to the bobbin on the speed frame is typical as with any other cotton roving system. For example, clockwise rotation of the flyer can give “Z” twist. Alternatively, the roving can have an “S” twist, by reversing the direction of the rotation of the flyer to a counter-clockwise direction. The roving hank ranges from about 0.5 to about 2.5 hanks. In one example, the hank of roving can be about 0.58. In yet another example, the hank of roving can be about 1.00.

After the roving step, a yarn spinning step converts the roving into single end yarn. In accordance with illustrated embodiment, yarn spinning is accomplished on a ring spinning system using typical settings for forming ring spun yarns. The spinning parameters on the ring spinning system are set based on the type of fibers in the overall yarn structure. The ring spinning frame can produce single end yarns with a count that ranges from about 8 Ne (664 denier) to about 140 Ne (37.9 denier). Yarns used for flat woven fabric may have a count that ranges from Ne to about 120 Ne (44.3 denier).

Yarn spinning is also accomplished on a rotor spinning system using typical settings for forming open end yarns. The spinning parameters on the rotor spinning system are set based on the type of fibers in the overall yarn structure. The rotor spinning system can produce single open end yarns.

Yarn spinning is also accomplished on a friction spinning system using typical settings for forming single end yarns. The spinning parameters on the friction spinning system are set based on the type of fibers in the overall yarn structure. The friction spinning system can produce single end yarns.

Yarn spinning is also accomplished on a self-twist spinning system using typical settings for forming single end yarns. The spinning parameters on the self-twist spinning system are set based on the type of fibers in the overall yarn structure. The self-twist spinning system can produce single end yarns.

Yarn spinning is also accomplished on an electro-static spinning system using typical settings for forming single end yarns. The spinning parameters on the electro-static spinning system are set based on the type of fibers in the overall yarn structure. The electro-static spinning system can produce single end yarns.

Yarn spinning is also accomplished on a vortex spinning system using typical settings for forming single end yarns. The spinning parameters on the vortex spinning system are set based on the type of fibers in the overall yarn structure. The vortex spinning system can produce single end yarns.

Yarn spinning is also accomplished on an air jet spinning system using typical settings for forming single end yarns. The spinning parameters on the air jet spinning system are set based on the type of fibers in the overall yarn structure. The air jet spinning system can produce single end yarns.

Yarn spinning is also accomplished on a twist less spinning system using typical settings for forming single end yarns. The spinning parameters on the twist less spinning system are set based on the type of fibers in the overall yarn structure. The twist less spinning system can produce single end yarns.

After yarn spinning, the yarn is further packaged into suitable yarn packages using auto-corners. Those packages are then used in a plying step for making multi ply yarn wherever required. In plying step, the yarns plied into multi ply yarn. In accordance with the illustrated embodiment, the plying step uses two-for-one twisters to twist two single end yarns into a two-ply yarn. Accordingly, as shown, the intermediate plied staple yarn is a two-ply yarn that includes a first staple yarn and a second staple yarn twisted with the first staple yarn to define the plied yarn. The intermediate plied yarn can have an overall twist per inch (TPI) from about 3.5 to about 14.5 TPI in an “S” direction. The twist direction can, however, be in a “Z” direction. Furthermore, the twist configuration can be either Z over S or Z over Z. The resultant yarn counts would be from about 2/10s to about 2/120s. In alternative embodiments, the intermediate plied yarn can be 3-ply yarn. Such a 3-ply intermediate yarn includes a first staple yarn, a second staple yarn, and a third staple yarn twisted into a plied structure. More plies than 3 can be used as needed. After yarn plying, the plied yarns are wound onto suitable yarn packages for further processing. For example, the plied yarn can be cross-wound onto a yarn package.

As a next step, the plied yarns proceed to a warping step. The warping step includes typical warping operations for flat woven fabrics.

A weaving step follows warping. The weaving step converts the yarns into woven fabrics. One or more looms, e.g. projectile, air-jet looms, rapier looms, water-jet looms (or others) can be used during the weaving step. Each loom may utilize typical shedding mechanism, such as a cam, dobby or jacquard type shedding mechanism. During the weaving step for the woven fabric 1, the warp and weft yarns can be arranged into a number of different weaving constructions and designs as is known by persons of skill in the art and that detailed above. For instance, the flat woven fabrics may include a plain weave, twills, rib weaves, basket weaves, percale, satins, sateens, other woven designs. In accordance with an embodiment of the present disclosure, the weaving step forms a woven fabric to have a) a warp end density between about 50 warp ends per inch and about 550 warp ends per inch; and b) a weft end density between about 50 weft yarns per inch and about 1500 weft yarns per inch (or more). In one example, the weft yarn density is between about 100 and about 1500 weft yarns per inch. Furthermore, the flat woven fabrics may have thread counts ranging from 100 TC to about 2000 T C. The weaving step may include co-insertion or insertion of multiple picks during a single pick insertion event. In one example, the weaving step includes inserting between one (1) weft yarn and seven (7) weft yarns during a single insertion event along the weft insertion path. Furthermore, for woven fabrics, the weft yarns, warp yarns, or both the warp and weft yarns can include the staple spun yarn or filament yarn. The flat woven fabrics are formed to have constructions that are suitable for bedding applications in both consumer, hospitality and/or healthcare markets.

The weaving step results in “greige fabrics” that are further processed into textile articles. After the weaving step, the greige fabrics are inspected. Following inspection, the natural as well as synthetic fabrics can either undergo a batch dyeing or a continuous dyeing.

The batch dyeing includes pretreatment namely desizing, scouring, bleaching, and dyeing; dyed in a typical fashion in a fabric dyeing machine. The operating temperature is maintained in a range from about 50° C. to about 120° C. The operating temperature for natural fabrics is maintained in a range from about 50° C. to about 80° C. The operating temperature for manmade fabrics is maintained in a range from about 95° C. to about 120° C. Batch dyeing may follow high temperature high pressure (HTHP) dyeing to make color the PET part. The operating temperature for natural and manmade fabrics blend is maintained at its respective temperature and condition as captured herein before. The batch dyeing step utilizes a liquor ratio sufficient to facilitate the overall process, and allow is free movement of the fabric in the dyeing machine. The liquor ratio may range from about 1:5 to about 1:30. For example, the liquor ratio may be 1:5, 1:10, 1:12, 1:15, 1:20, 1:25, 1:22, or 1:28.

During batch dyeing step, the fabrics are typically wound into the shape of a rope prior to entering the fabric-dyeing machine. The rotation of the fabric in rope form aids in uniform pretreatment and dyeing. Finishing is an optional step may be used to apply any specialty chemicals if required. After pretreatment and dyeing operation is over the fabric can be rinsed and neutralized and followed by unloading from the dyeing vessel. After unloading the woven fabrics from the vessel, the water is extracted material in an extractor in the typical manner to reduce the moisture content from 200% to 60%. A rope is passed through rope opener, which is equipped with drumbeaters both at feed and delivery ends, to straighten the twist in the rope. Then the material is passed two times through a hot air dryer which is equipped with drumbeaters at both the feed and delivery ends. This ensures proper lifting of the pile. The first drying is carried out at about 120° C. The second drying occurs at a higher temperature, such as 150° C. for about 4 minutes to about 5 minutes. The full width fabric is then passed through hot air stenter and a weft straightener to straighten the fabric and return it to its proper dimensions.

As described above, after the inspection step, the greige fabric can processed using continuous dyeing range in a continuous dyeing step using process temperature and conditions as applicable to respective fiber or blends. After the continuous dyeing step the woven fabric is dried. The drying step utilizes a hot air dryer to further dry the fabrics at the desired temperature. The dried fabric is expanded to full width and then passed through a stentering step. The stentering step can help straighten the fabric. Finishing is an optional step may be used to apply any specialty chemicals if required.

Following the stentering step (or optional shearing step), a cutting step cuts the woven fabrics to the desired length and width depending on the particular end use.

For flat woven fabrics, after cutting, the cut woven fabric is stitched.

Following a cutting step, the cut woven fabric can be stitched in various options to form the bedding article. In one option, the woven fabric for the top cover is consisting of flat fabric of natural fiber and/or natural fiber blends and/or natural and manmade fiber blends. The woven fabric for the drop area is consisting of flat fabric of manmade fiber and/or manmade fiber blends. The drop area is stitched around the top cover. The drop area is stitched with or without gathering effect. Four elastic bands are stitched at all four corners at tangential way at the bottom end of the drop area. The gathering effect is in the range of 2:1 or 2:1.5. In this option, the stitched top cover and drop area is suitable for fitting the mattresses with drop area of 8 inch to 20 inch.

In another option, the woven fabric for the top cover is consisting of flat fabric of natural fiber and/or natural fiber blends and/or natural and manmade fiber blends. The woven fabric for the drop area is consisting of flat fabric of manmade fiber and/or manmade fiber blends. The drop area is stitched around the top cover. The drop area is stitched with or without gathering effect. The gathering effect is in the range of 2:1 or 2:1.5. Four elastic bands are stitched at all four corners at tangential way at the bottom end of the drop area. In this option, the stitched top cover and drop area is suitable for fitting the mattresses with drop area of 8 inch to 20 inch.

In another option, the woven fabric for the top cover is consisting of flat fabric of natural fiber and/or natural fiber blends and/or natural and manmade fiber blends. The woven fabric for the drop area is consisting of flat fabric of manmade fiber and/or manmade fiber blends. The drop area is stitched around the top cover along with elastic band. The drop area is stitched with or without gathering effect. The gathering effect is in the range of 2:1 or 2:1.5. Four elastic bands are stitched at all four corners at tangential way at the bottom end of the drop area. In this option, the stitched top cover and drop area is suitable for fitting the mattresses with drop area of 8 inch to 20 inch.

In another option, the woven fabric for the top cover is consisting of flat fabric of natural fiber and/or natural fiber blends and/or natural and manmade fiber blends. The woven fabric for the drop area is consisting of flat fabric of manmade fiber and/or manmade fiber blends. The drop area is stitched around the top cover. The drop area is stitched with or without box pleating effect. Four elastic bands are stitched at all four corners at tangential way at the bottom end of the drop area. In this option, the stitched top cover and drop area is suitable for fitting the mattresses with drop area of 8 inch to 20 inch.

In another option, the woven fabric for the top cover is consisting of flat fabric of natural fiber and/or natural fiber blends and/or natural and manmade fiber blends. The woven fabric for the drop area is consisting of flat fabric of manmade fiber and/or manmade fiber blends. The drop area is stitched around the top cover along with elastic band. The drop area is stitched with or without box pleating effect. Four elastic bands are stitched at all four corners at tangential way at the bottom end of the drop area. In this option, the stitched top cover and drop area is suitable for fitting the mattresses with drop area of 8 inch to 20 inch.

In another option, the woven fabric for the top cover is consisting of flat fabric of natural fiber and/or natural fiber blends and/or natural and manmade fiber blends. The woven fabric for the drop area is consisting of flat fabric of manmade fiber and/or manmade fiber blends. The drop area is stitched around the top cover along with self-piping. The bottom end of the drop area is further stitched with the elastic band all around. In this option, the stitched top cover and drop area is suitable for fitting the mattresses with drop area of 8 inch to 20 inch.

In another option, the woven fabric for the top cover is consisting of flat fabric of natural fiber and/or natural fiber blends and/or natural and manmade fiber blends. The woven fabric for the drop area is consisting of flat fabric of manmade fiber and/or manmade fiber blends. The drop area is stitched around the top cover along with contrast piping. The bottom end of the drop area is further stitched with the elastic band. In this option, the stitched top cover and drop area is suitable for fitting the mattresses with drop area of 8 inch to 20 inch.

In another option, the woven fabric for the top cover is consisting of flat fabric of natural fiber and/or natural fiber blends and/or natural and manmade fiber blends. The woven fabric for the drop area is consisting of flat fabric of manmade fiber and/or manmade fiber blends. The drop area is stitched around the top cover along with either self or contrast flat and cord piping. The bottom end of the drop area is further stitched with the elastic band all around. In this option, the stitched top cover and drop area is suitable for fitting the mattresses with drop area of 8 inch to 20 inch.

In another option, the woven fabric for the top cover is consisting of flat fabric of natural fiber and/or natural fiber blends and/or natural and manmade fiber blends. The woven fabric for the drop area is consisting of flat fabric of manmade fiber and/or manmade fiber blends/or Natural fiber/or natural fiber blend/or natural and manmade blend. The drop area is stitched around the top cover along with contrast piping. The bottom end of the drop area is further stitched with the elastic band. In this option, the stitched top cover and drop area is suitable for fitting the mattresses with drop area of 8 inch to 20 inch.

In another option, the woven fabric for the top cover is consisting of flat fabric of natural fiber and/or natural fiber blends and/or natural and manmade fiber blends. The woven fabric for the drop area is consisting of flat fabric of manmade fiber and/or manmade fiber blends/or Natural fiber/or natural fiber blend/or natural and manmade blend. The drop area is stitched around the top cover. The bottom end of the drop area is further stitched with the elastic band all around. The four corners of the drop area are further stitched with T shaped elastic bands. In this option, the stitched top cover and drop area is suitable for fitting the mattresses with drop area of 8 inch to 20 inch.

In another option, the woven fabric for the top cover is consisting of flat fabric of natural fiber and/or natural fiber blends and/or natural and manmade fiber blends. The woven fabric for the drop area is consisting of flat fabric of manmade fiber and/or manmade fiber blends. The drop area is stitched around the top cover. The bottom end of the drop area is further stitched with the velcro bands. The one corners of the drop area is stitched with hook side and the next adjoining corner is stitched with the extendible loop side to connect the hook side. In this option, the stitched top cover and drop area is suitable for fitting the mattresses with drop area of 8 inch to 20 inch.

In another option, the woven fabric for the top cover is consisting of flat fabric of natural fiber and/or natural fiber blends and/or natural and manmade fiber blends. The woven fabric for the drop area is consisting of flat fabric of manmade fiber and/or manmade fiber blends. The drop area is stitched around the top cover. The bottom end of the drop area is further stitched with the zip fastener. The one corners of the drop area is stitched with one side of the zipper and the next adjoining corner is stitched with the extendible other side of the zipper and a runner is used to complete the zipper system. In this option, the stitched top cover and drop area is suitable for fitting the mattresses with drop area of 8 inch to 20 inch.

In another option, the woven fabric for the top cover is consisting of flat fabric of natural fiber and/or natural fiber blends and/or natural and manmade fiber blends. The woven fabric for the drop area is consisting of flat fabric of manmade fiber and/or manmade fiber blends. The drop area is stitched around the top cover. The bottom end of the drop area is further stitched with the snap fastener. The snap could be any type in metal or non-metal options. In this option, the stitched top cover and drop area is suitable for fitting the mattresses with drop area of 8 inch to 20 inch.

While the disclosure is described herein using a limited number of embodiments, these specific embodiments are not intended to limit the scope of the disclosure as otherwise described and claimed herein. The precise arrangement of various elements and order of the steps of articles and methods described herein are not to be considered limiting. For instance, although the steps of the methods are described with reference to sequential series of reference signs and progression of the blocks in the figures, the method can be implemented in a particular order as desired.

Claims

1. A bedding article, comprising:

a top cover having a perimeter and formed from a first flat woven fabric, the first flat woven fabric having a warp component including warp yarns and a weft component including weft yarns interwoven with the warp yarns to define the flat woven fabric, wherein at least one of a) the warp component and b) the weft component comprise a plurality of the staple spun yarns; and

a durable drop area with quick dry property stitched to the perimeter of the top cover, the drop area formed from a second flat woven fabric that is different from the first woven fabric, the second flat woven fabric having a warp component including warp yarns and a weft component including weft yarns interwoven with the warp yarns to define the flat woven fabric, wherein at least one of a) the warp component and b) the weft component includes staple spun yarns or filament yarns each made of man-made fibers.

2. The bedding article according to claim 1, wherein the man-made fibers of the staple spun yarns or filament yarns of the second flat woven fabric are either circular cross-section fibers or non-circular cross-section fibers or combination of both.

3. The bedding article according to claim 1, wherein the staple spun yarns for the first flat woven fabric are single end yarns or multi-ply yarns.

4. The bedding article according to claim 1, wherein the staple spun yarns for the first flat woven fabric include only natural fibers and man-made cellulosic fibers.

5. The bedding article according to claim 1, wherein the staple spun yarns for the first flat woven fabric include an intimate blend of natural fibers, man-made cellulosic fibers, and other man-made fibers.

6. The bedding article according to claim 1, wherein the staple spun yarns for the second flat woven fabric are single end spun yarns or multi-ply spun yarns.

7. The bedding article according to claim 1, wherein the filament yarns for the second flat woven fabric are monofilament yarns or multi-filament yarns.

8. The bedding article according to claim 1, wherein a) the warp component and b) the weft component of the second flat fabric includes filament yarns but not staple spun yarns.

9. The bedding article according to claim 1, wherein a) the warp component and b) the weft component of the second flat fabric includes staple spun yarns but not filament yarns.

10. The bedding article according to claim 6, wherein the man-made fibers of the second flat woven fabric are polyester fibers.

11. The bedding article according to claim 1, wherein the drop area is stitched to the top cover with at least one pleat or a gathering effect.

12. The bedding article according to claim 1, further comprising either:

a. four elastic bands attached to a bottom end of the drop area at corners of the bedding article; or

b. four elastic T-bands attached at the corners of the bedding article.

13. The bedding article according to claim 1, wherein an entirety of a bottom end of the drop area includes an elastic band.

14. The bedding article according to claim 1, wherein the drop area is stitched to an entirety of the perimeter of the top cover with one of the following: an elastic band, a piping, a contrast piping, a cord piping, a flat piping.

15. The bedding article according to claim 1, wherein the drop area includes one of the following:

a) a hook and loop fastener at one corner of the drop area;

b) a zipper at one corner of the drop area; or

c) a snap fastener at one corner of the drop area.

16. A method for manufacturing a bedding article, comprising:

weaving a first flat woven fabric, the first flat woven fabric having a warp component including warp yarns and a weft component including weft yarns interwoven with the warp yarns to define the flat woven fabric, wherein at least one of a) the warp component and b) the weft component comprise a plurality of the staple spun yarns; and

weaving a second flat woven fabric, the second flat woven fabric having a warp component including warp yarns and a weft component including weft yarns interwoven with the warp yarns to define the flat woven fabric, wherein at least one of a) the warp component and b) the weft component includes staple spun yarns or filament yarns each made of man-made fibers;

cutting the first flat woven fabric into a top cover having a perimeter;

cutting the second flat woven fabric into a drop area; and

stitching the drop area to the perimeter of the top cover to form the bedding article.