000001
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`BEDGEAR 1004
`IPR of U.S. Pat. No. 8,402,580
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`Patent Application Publication Dec. 29, 2005 Sheet 1 of 2
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`US 2005/0284189 A1
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`FIG. 1
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`FIG. 1A
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`Patent Application Publication Dec. 29, 2005 Sheet 2 of 2
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`US 2005/0284189 A1
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`FIG. 2
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`US 2005/0284189 A1
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`Dec. 29, 2005
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`CIRCULAR-KNIT BED SHEET
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`BACKGROUND OF INVENTION
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`[0001]
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`1. Field of the Invention
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`[0002] This invention is directed to bed sheets and the like,
`and more particularly,
`to circular-knit bed sheets and the
`like.
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`[0003]
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`2. Description of Related Art
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`[0004] Since the early 1990s, the U.S. healthcare market-
`place has made a decided and easily-discernible shift from
`woven to knitted contour or “fitted” sheets and, to a lesser
`extent, knitted pillow cases, flat sheets, draw sheets, and the
`like. These knitted products are perceived to be of greater
`utility because of the wider range of bed, mattress, and
`pillow sizes for which such products may be utilized.
`
`[0005] Most commonly, these knit fabrics are made with
`a blend of cotton yarns and/or cotton/polyester yarns,
`although some 100% cotton versions are available in the
`marketplace. One product is known to exist which incorpo-
`rates 4% spandex elastomeric yarn, in combination with
`cotton/polyester spun yarns. (See Menaker U.S. Pat. No.
`6,164,092).
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`[0006] As usage of these products has increased, several
`issues concerning product durability have been identified.
`Specifically, these include the high propensity of circular-
`knit fabrics to develop “pinholes” caused by breaks in the
`knitted chain structure, and to undergo “chaining” where the
`sheet, in essence, tears apart along a broken thread line.
`Also, such products tend to have relatively poor dimensional
`stability as compared with woven fabrics. These issues
`further include a recognition that suitable commercial dura-
`bility is only reasonably achieved by increasing overall
`fabric weight to a level much higher than that of traditional
`woven goods. However, such an increase in fabric weight
`increases acquisition- and processing-expenses.
`SUMMARY OF INVENTION
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`[0007] The present invention provides circular-knit bed-
`ding, such as bed sheets and the like, having a greater
`durability than products made with conventional circular-
`knit fabrics, without an overall increase in fabric weight and
`the corresponding acquisition- and processing-costs, and
`without sacrificing the comfortable feel of the bedding. To
`this end, and in accordance with the principles of the
`invention, the durability enhancement is accomplished by
`non-pile circular-knitting at least one spun yarn and at least
`one synthetic filament yarn,
`the synthetic filament yarn
`being without
`loose filament-ends sticking out along its
`length, and further having an elongation-at-break of not
`more than 50%. Abed sheet, or other bedding product, may
`be made by converting a length of the resulting non-pile
`circular-knit fabric into the desired product.
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`[0008] By virtue of the foregoing, there is thus provided a
`circular-knit fabric and bedding which provide enhanced
`durability while maintaining a comfortable feel, and without
`increasing overall fabric weight. These and other advantages
`of the present invention will be apparent from the accom-
`panying drawings and description of the drawings.
`BRIEF DESCRIPTION OF DRAWINGS
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`[0009] The accompanying drawings, which are incorpo-
`rated in, and constitute a part of this specification, illustrate
`
`embodiments of the invention, and, together with the general
`description of the invention given above, and the detailed
`description of the drawings given below, serve to explain the
`principles of the invention. The drawings are schematic, and
`are not to scale.
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`[0010] FIG. 1 is a perspective view of a tube of non-pile
`circular-knit fabric in accordance with the principles of the
`invention;
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`[0011] FIG. 1A is an enlarged fragmentary elevational
`view of a portion of the fabric of FIG. 1;
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`[0012] FIG. 2 is a perspective view of the fabric of FIG.
`1, with the tube having been slit open;
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`[0013] FIG. 3 is a perspective view of a roll of the
`non-pile, circular-knit fabric of FIG. 2; and
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`[0014] FIG. 4 is a perspective view of a fitted sheet made
`from a length of fabric taken from the roll of FIG. 3, in
`accordance with the principles of the invention. For pur-
`poses of illustration, the fitted sheet is oriented as if it were
`positioned in place on a mattress (not shown).
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`DETAILED DESCRIPTION OF THE DRAWINGS
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`[0015] With reference to FIGS. 1 and 1A, a tube 10 of
`non-pile circular-knit fabric 12 is circular-knit in a conven-
`tional fashion with a plurality of series of loops of yarn, with
`at least one yarn being a spun yarn 14 and at least another
`yarn being a synthetic filament yarn 16. The synthetic
`filament yarn 16 has an elongation-at-break of not more than
`about 50%, and does not have loose filament-ends sticking
`out along its length. The resulting non-pile circular-knit
`fabric 12 has a plurality of courses, as at 18, running across
`the fabric (i.e.,
`transverse to the longitudinal axis 20
`thereof), and a plurality of wales, as at 22, running the length
`of the fabric 12 (i.e., parallel to axis 20). The tube 10 may
`be slit open by making a cut in the endless circumferential
`sidewall 24 of the tube 10, with the cut running the length
`of the tube 10 and being parallel to the longitudinal axis 20
`thereof, as at the line 26. Once the cut is made, the fabric 12
`may be laid open as indicated by the arrows 28a, b into an
`elongated sheeting as seen in FIG. 2. The opened fabric 12
`has a first lengthwise edge 30 and a second lengthwise edge
`32, both having been created by the longitudinal cut 26.
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`[0016] With reference to FIGS. 2 and 3, the opened fabric
`12 then may be rolled up in a direction parallel to axis 20,
`thereby forming a roll 34 of the fabric 12 for use in
`subsequent processing steps. The first and second length-
`wise edges 30, 32 of the opened fabric 12 also are visible on
`the rolled-up fabric 12.
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`[0017] As will be appreciated, the spun yarn 14 may be
`made of any suitable material or combination of materials.
`For example, the spun yarn 14 may be 100% cotton or a
`combination of cotton and other material(s). If all-cotton
`yarn is used, such yarn advantageously may have a yarn
`count in the range of about 20 singles to about 30 singles.
`The synthetic filament yarn 16 may be made of any suitable
`material or combination of materials. For example, polyester
`or other acceptable polymers may be used. In addition, the
`filament yarn 16 may have any suitable denier. For example,
`the yarn 16 may have a denier in the range of about 50 to
`about 300, or about 75 to about 150. Also, the yarn 16 may
`be a singles yarn, a plied yarn, or other suitable yarn type.
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`US 2005/0284189 A1
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`Dec. 29, 2005
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`If desired, the yarn 16 may be a 150 denier, 48 filament,
`polyester yarn. The spun yarn 14 and synthetic filament yarn
`16 may have any other suitable characteristics, as desired,
`including for example, any suitable spun-yarn count or
`counts.
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`[0018] The non-pile circular-knit fabric 12 may have any
`suitable ratio or ratios of spun yarn 14 to synthetic filament
`yarn 16. For example, if the spun yarn 14 is a 100% cotton
`yarn, the spun yarn 14 may represent about 55% to about
`60% by weight, and the synthetic filament yarn 16 may
`represent from about 40% to about 45% by weight. Also, if
`desired, the fabric 12 may have a fabric weight of about 100
`to about 250 grams per square meter (g/m 2).
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`[0019] With reference to FIG. 4, a fitted bed sheet 36
`made from a length of fabric taken from the fabric roll 34
`(FIG. 3) has a first lengthwise edge 38 corresponding with
`the first lengthwise edge 30 of the fabric 12, and a second
`lengthwise edge 40 corresponding with the second length-
`wise edge 32 of the fabric 12. The sheet 36 further includes
`a first sidewall 42 adjacent
`the first edge 38, a second
`sidewall 44 adjacent the second edge 40, a head wall 46, an
`end wall 48, and a top wall 50 extending therebetween. In
`addition, the sheet has an edge 52 adjacent the head wall 46,
`an edge 54 adjacent the end wall 48, a seam 55a, b, C, d at
`each corner of the sheet 36, and a binding strip 56 sewn to
`the sheet 36 adjacent the edges 38, 40, 52, and 54.
`
`[0020] The sheet 36 may be made from the fabric 12 using
`customary methods and equipment, including, for example,
`any desired finishing treatment(s), cutting, and sewing.
`Examples of finishing treatments include the application of
`an antimicrobial finish, a flame-retardant finish, a no-iron
`finish, a no-stain finish, an optical brightener, and/or a color.
`As would be appreciated by one of ordinary skill, such
`finishing treatments may be applied to the yarns used to form
`a non-pile circular-knitted fabric,
`to a non-pile circular-
`knitted fabric in its greige state, and/or to the sheets or other
`bedding items which are made from the fabric. As also
`would be appreciated, one or more of the converting- or
`finishing-aspects may include cutting and removing a piece
`of fabric from each corner of a to-be-completed fitted sheet,
`and seaming the remaining corner fabric to form the various
`walls and edges of the sheet. Another aspect may include
`sewing of a binding strip to one or more of the edges. For
`example, a binding strip (not shown) may be sewn to each
`of the first and second elongated edges 30, 32 of the fabric
`12 shown in FIG. 2. Alternatively, such binding strips may
`be sewn to elongated lengthwise edges of a length of fabric
`(not shown) cut from the roll 34 of fabric 12 shown in FIG.
`3. In addition, as will be appreciated by one of ordinary skill,
`a binding strip or strips may be sewn to any of the exposed
`edges of a length of fabric during the formation of the fitted
`sheet 36 (FIG. 4) or any other bedding product made from
`the non-pile circular-knit fabric 12.
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`In use, a non-pile, circular-knit fabric may be
`[0021]
`formed, in which the fabric includes at least one spun yarn
`and at least one synthetic filament yarn, with the synthetic
`filament yarn having an elongation-at-break of not more
`than about 50% and being without
`loose filament-ends
`sticking out along its length. Individual sheets and other
`bedding products then may be made from the fabric.
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`[0022] The non-pile circular-knit greige fabric, the par-
`tially-converted or partially-finished fabric, and the bed
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`sheets and other bed-sheeting products described above
`provide several benefits and advantages. For example, the
`non-pile circular-knit bedding has a durability greater than
`that of products made with conventional circular-knit fab-
`rics, without an overall increase in fabric weight and the
`corresponding acquisition- and processing-costs. Further-
`more, this enhanced durability is achieved without sacrific-
`ing the comfortable feel of the bedding.
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`there is a non-pile
`[0023] By virtue of the foregoing,
`circular-knit fabric, as well as bedding products made from
`the fabric, both of which have advantages over prior circu-
`lar-knit fabrics and bedding made from those fabrics.
`
`[0024] While the present invention has been illustrated by
`a description of embodiments, and while the illustrative
`embodiments have been described in considerable detail, it
`is not the intention of the inventor to restrict or in any way
`limit
`the scope of the appended claims to such detail.
`Additional advantages and modifications readily will appear
`to those skilled in the art. For example, any given fabric of
`the invention may include a plurality of spun yarns and/or a
`plurality of synthetic filament yarns. Furthermore, one or
`more of the plurality of spun yarns may have a characteristic
`or characteristics different from that of another of the spun
`yarns. Likewise, one or more of the plurality of synthetic
`filament yarns may have a characteristic or characteristics
`different from that of another of the synthetic filament yarns.
`Also, although one of the drawings illustrates a fitted bed
`sheet, the fabrics of the invention may be used to form flat
`sheets, blankets,
`towels, pillow cases, and other sized-
`specific flat-goods. The invention in its broader aspects is
`therefore not limited to the specific details, representative
`apparatus and methods, and illustrative examples shown and
`described. Accordingly, departures may be made from such
`details without departing from the spirit or scope of the
`inventor’s general inventive concept.
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`What is claimed is:
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`1. A bed sheet, comprising:
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`a non-pile circular-knit fabric, the fabric comprising at
`least one spun yarn and at least one synthetic filament
`yarn,
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`the synthetic filament yarn being without loose filament-
`ends sticking out along its length, the synthetic filament
`yarn further having an elongation-at-break of not more
`than about 50%.
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`2. The bed sheet of claim 1 wherein the elongation-at-
`break is in the range of from about 10% to about 50%.
`3. The bed sheet of claim 1 wherein the fabric includes a
`finish.
`4. The bed sheet of claim 3 wherein the finish is one or
`more of an antimicrobial finish or a flame-retardant finish.
`5. The bed sheet of claim 1 wherein the bed sheet includes
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`at least one edge and a binding strip sewn at the edge.
`6. The bed sheet of claim 1 wherein the fabric comprises
`a plurality of spun yarns and a plurality of synthetic filament
`yarns.
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`7. A method of making a bed sheet, comprising:
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`obtaining a length of non-pile circular-knit fabric, the
`fabric comprising at least one spun yarn and at least one
`synthetic filament yarn,
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`US 2005/0284189 Al
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`Dec. 29, 2005
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`the synthetic filament yarn being without loose filament-
`ends sticking out along its length, the synthetic filament
`yarn further having an elongation-at-break of not more
`than about 50%; and
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`converting the length of non-pile circular-knit fabric into
`a bed sheet.
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`8. The method of claim 7 wherein the elongation-at-break
`is in the range of from about 10% to about 50%.
`9. The method of claim 7 further comprising applying a
`finishing treatment to the length of non-pile circular-knit
`fabric.
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`10. The method of claim 7 wherein converting includes
`cutting a portion of the non-pile circular-knit fabric from the
`length thereof.
`11. The method of claim 7 wherein the length of non-pile
`circular-knit
`fabric includes
`an edge,
`and converting
`includes sewing a binding strip at the edge.
`12. The method of claim 7 wherein the fabric comprises
`a plurality of spun yarns and a plurality of synthetic filament
`yarns.
`13. A method of making a fabric for use in making a bed
`sheet, comprising:
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`obtaining at least one spun yarn and at least one synthetic
`filament yarn, the synthetic filament yarn being without
`loose filament-ends sticking out along its length, the
`synthetic filament yarn further having an elongation-
`at-break of not more than about 50%; and
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`non-pile circular-knitting the spun yarn and the synthetic
`filament yarn so as to form a fabric.
`14. The method of claim 13 wherein the elongation-at-
`break is in the range of from about 10% to about 50%.
`15. The method of claim 13 further including applying a
`finishing treatment.
`16. The method of claim 15 wherein the finishing treat-
`ment is applied to the fabric.
`17. The method of claim 13 wherein the fabric comprises
`a plurality of spun yarns and a plurality of synthetic filament
`yarns.
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`18. A method of making a flat-good textile product,
`comprising:
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`obtaining a length of non-pile circular-knit fabric, the
`fabric comprising at least one spun yarn and at least one
`synthetic filament yarn,
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`the synthetic filament yarn being without loose filament-
`ends sticking out along its length, the synthetic filament
`yarn further having an elongation-at-break of not more
`than about 50%; and
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`converting the length of non-pile circular-knit fabric into
`a flat-good textile product.
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