WC 2010!03 7082
`
`PCTlUS20l]9!058';'16
`
`4M
`
`§34a
`
`3453
`
`38
`
`32
`
`'
`
`éssm
`K»
`
`‘Fig. 4
`
`000801
`
`BEDGEAR 1008 (part 9)
`
`IPR of U.S. Pat. No. 8,402,580
`
`

`
`(12) INTERNATIONAL APPLICATION PUBLISHED UNDER THE PATENT COOPERATION TREATY {PCT}
`
`(l9) World Intellectual Property Organization
`International B1u'caL1
`
`(43) International Publication Date
`
`1 April 2010 (01.04.2010) (10) International Publication Number
`
`WO 2010/037082 A3
`
`(51)
`
`International Patent Classificatio-1|:
`D043 2?/14' [3U[)6.l']l]
`D030 If/tIl'E}(3[)(Jfi.[i1)
`
`{B1}
`
`(11)
`
`International Applicafiun Number:
`
`PCT.-’Ut33[)[)9."[l587 l 6
`
`(22)
`
`International Filing Date:
`29 September 3009 (29.09.2009)
`
`(25)
`
`Filing Language:
`
`English
`
`English
`
`US
`
`(26)
`
`(30)
`
`(71)
`
`(72)
`(75)
`
`Publication Language:
`
`Priority Data:
`6]r'lUl ,0-49
`39 Septeinber 2008 (29.09.2008)
`
`Applicant (fit? aft’ desigitnted States c=.rc'€pt' US): SHEEX
`L-LC [USFUS]; 169 Captain Lowman Road, Cliapin, SC‘
`29036 [US].
`
`Inventors; and
`Inventors.-‘Applicants ffoi‘ US omft=): WALVIUS, Susan.
`Katherine [USKUS]; I69 Captaiii Luwrnan Road, Chalpin,
`SC 29030
`(US).
`}’I.-\RCl\'I:'\K..
`[\'liche]]e.. Nlarie
`[USIUS]; 169 Captain I_UW'l'l'l.i:l.11 Road, Chopin, SC 39036
`(US).
`
`(74)
`
`2%.; Trotilinan Sanders
`Agent: SCHNEIDER. Ryan.
`LLP, Bank of America Plaza, -600 Pcachtroe Street, NE,
`Suite 5300, Atlanta, GA 30308-2216 (US).
`
`Desigtlated States fttniess aI.I':e.r1.vt's'e .i'J?.t1".t'C'£T.t'C’C!',‘,i'rh)iP' einistfv
`kind afnarioncri p.rn.rec.'i'mt at-'m'i'afJl'£): Alf, AG, AL, AM,
`AU, AT, AU, AZ, BA, HI}, HU, HI], HR, I3“-’, HY, HZ,
`CA, CH, CL, CN, CO, CR, CU, CZ, DE, DK, DM, DO,
`DZ, EC, EE, EG, ES, FI, GB, GD, GE, GH, GM, GT,
`HN, HR, HU, ID, IL, IN, IS, JP, KE, KG, KM, KN, KP,
`KR, KZ, LA, LC, LK, LR, LS, LT, LU, LY, MA, MD,
`ME, MG. MK, MN, MW, MX,
`IVIY, MZ, NA, NG. NI,
`NO, NZ, OM, PE, PG, PH, PL, PT, RC), RS, RU, SC. SD,
`SE, SG, SK, SL, SM. ST, SV, SY, TJ, TM, TN, TR, TT,
`TZ, UA, UG, US, UZ, VC, VN, ZA, ZM, ZW'.
`
`(34)
`
`Designated States i_'um’ess oritenvisc iirdicwrred. for eve.~_1=
`fried qfregionnt’ _prorccrfon ctmfinbfe}: ARIPO {BW, GH,
`GM, KP, LS. MW, MZ, ‘NA, SD, SL, SZ, TZ. UG, ZM,
`ZW), Iitlrasialt {AM, AZ, BY, KG, KZ, Ml), RU, TJ,
`TM), European (AT, BE, BG, CH, CY, CZ, DE, DK, EE,
`ES, FI, FR, GB, GR, HR, HU, IE, IS, IT, LT, LU, LV,
`MC, MK, MT, NL, NO, PL, PT, RO, SE, SI, SK, SM,
`TR), OAPI (BF, BJ, CF, CG, CI, CM, GA, GN, GQ, GW,
`ML, MR, NE, SN, TD, TG).
`Published:
`
`1-viii: i'ii.rr:.='m1r.'.i'o-imils'earc'Pi report (Art. 21(3))
`bqirre the e.r_zu‘rart'on of the mm’ firm"! fiwr ameiidirrg the
`ct’m'ms' and to be repubiis-!rt.>a’ in Have (.’I’(.’i’:|'!
`:3-f'r<?t:'t?i}t9i of"
`nmertdmen ts (Rule 48. 2 Ht),1
`
`,’Com‘i'ntred on next‘ page!
`
`(54) Title: FABRIC SYSTEM
`
`7
`
`-
`
`.. .
`
`.
`
`..
`
`.'
`
`..---’
`
`I
`
`I,‘
`
`»
`
`_._,
`
`\,
`
`(57) Abstract: Bedding material "including :1 tlrst fabric section manutac-
`tured fmm pcrfonnancc fabric and having a first and second side; and, a
`second fabric section attached to the first side of the first fabric section.
`
`Additionally, a. third fabric sectiml cam be attached to the second side Ul'.‘ll'.It:
`first fabric section. The first fabric section can be attached to the second
`fabric section through a [Iallock slilch. The iirst fabric section can include
`at first zone and a second zone wherein the first zone colilains diflierenl per-
`formanee properties from the second zone and the first zone can liave ther-
`mal or moisture wicking properties.
`
`
`
`
`
`wo2010/037032A3||||||||||||||ll|||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
`
`338
`
`in
`
`
`!ll!1.!;!.*—*'1.'v.4[?.1i..l!.".!t.‘-|,!.J’!l[
`
`_
`
`_
`
`in
`
`flan
`
`000802
`
`
`
`
`
`
`
`

`
`
`
`WO 2010/037082 A3 ||||||||||||||||||I||||||||I|||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||I|WO 2010/037082 A3 ||||||||||||||||||I||||||||I|||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||I|
`
`
`(88) Date of puhlicatiun 0f the international search report:(88) Date of puhlicatiun 0f the international search report:
`
`8 J L11); 20108 J L11); 2010
`
`
`
`000803000803
`
`

`
`
`
`
`
`IntI.'1'nalional application No.
`
`PCTfUS2009r'0587 1 6
`
`A.
`CLASSIFICATION OF SUBJECT MATTER
`
`INTERNATIONAL SEARCH REPORT
`
`D043 21/.l'4(2t}l'06.0t')i, D03D I 1'/00(2006.0.l')i
`According to International Patent Classification (IPC) or to both national classification and IPC
`FIE. LDS SEA RCH ED
`
`Mi nirnum documentation searclied (classiticatioli system followed I33-' classification symbols)
`|Jt)4l-3 '2 l .*'l4', A47G '3).-"{ltJ', A-’lT(i 9.-'-02f. A616 7505: B32l;3 5.~"2Fa
`
`Doounientatioli searched other than Ininilnum documentation to the extent that such documents are included in the fields: searched
`
`Korean utility models and applications for utility models
`Japanese utility models and applications for utility models
`(Chinese Patents and application for patent)
`Electronic data basc constlltcd during. thc international scarch (nainc of data basc and. whcrc practicablc. scarch lcrms uscd)
`I:KOMTASS(KH’O intcrnali
`
`C.
`
`DOCUMENTS CONSIDERED TO BE RELEVANT
`
`Category “‘
`
`Citation o['doctIn'tent. with indication. where appropriate. of the relevant passages
`
`Relevant to claim No.
`
`X
`
`.3’.
`
`A
`
`A
`
`l{Y[.' KID 09 .\lovt=.-mljer
`JP l 1-30.‘-J l 83 A (MOTH [_'CHl
`See [::arag1‘aphs W001] and l0010l-l0013l
`
`199$}
`
`(Tl-l0l'tlPSOl\': THOl.l.-IS L.) 0'? lulay 2002
`US 5381779 Bl
`See claim 1 and figures 4-6
`
`ill
`US 38l.73Sl.l
`See column 1.
`
`(ROCK: MOSHE t!L al.l 06 C'L.‘l.{Jl){_‘t‘ 1993
`line 66 - column 3.
`line 19
`
`(}:lPtCl.}0l\'.1'tLDZ l{Ol.il£l~t'l'l 16 June 1995
`US 5765241 1'-ltl
`See the whole document
`
`l—l7
`
`1-1?
`
`l—17
`
`Bi!
`
`Pl A"
`
`..E..
`
`rlLl'
`
`El Further documents are listed in the continuation ofF!ox C‘.
`Special categories of cited docttments:
`doctunent defining the general state of the art which is not considered
`to be of partictllur rt:lt:vant:::
`earlier applicatioli or patent hut published on or ztfler the irrteniational
`filing date
`clocument which Inay tlircw doubts on priority c|aim(s) or which is
`cited to establish the publication date of citation or other
`special reason (as specified)
`document referring to an oral disclosure. use,
`]TI1.‘.{l11S
`
`H01!
`
`r2!x'l'IllJl‘li0t'1 or other
`
`up“
`
`document published prior to the international filing date but
`than the priority date claimed
`
`later
`
`E See patent l'amil_v annex.
`later do-.:un1c1it published alter the ilitcmalioual filing date or priority
`date and not
`in conflict with the application but cited to tlnderstand
`the principle or Il1¢t)l'_\-' underl}-'ing the invention
`document of paniculzir relevance; the claimed itwention cannot be
`considered novel or caruiot be colisidered to iiwc-lve an iiwemive
`step ‘Wilt-_‘I1
`the d()t_‘lI1TIi!I'Jl is taken alom-:
`document of panicular relevance;
`the claimed invention cannot be
`considered to involve an inventive step when the document
`is
`conibined with one or more other such dccuInents.s=11ch cornbiltaticli
`l1-eing obviotls to :1 person skilled in the art.
`document member of the same patent faniil}-'
`
`..-J‘-..
`
`“Y”
`
`..&..
`
`Date of the actual completion ofthc international search 23 APRIL 3010 (38.04.2010)
`
`Name and mailing address of the ISA.-‘KR
`
`Date of mailing ofthe international Search report
`
`29 APRIL 2010 (29.04.2010)
`Authorized officer
`
`Korean Intellectual Property (.}t'flc.e
`Govcrnmcnt Coniplcx-Dacjcon. l39 Sconsa-ro. Sco-
`gu, Dacjcon 302-70-J . Republic ot‘Korca
`Faoshnflelio. 32-42-472.7140
`
`KIM, Jc-ng Kyoo
`
`Tclcphonc No.
`
`82-42-48 [-5593
`
`Form PCT.-‘ISA.-"2 1U (second sheet) (.lI.Il}" 2009)
`
`000804
`
`

`
`INTERNATIONAL SEARCH REPORT
`
`Informatic-n an patent t‘a111i]3' members
`
`|nternat1'0na] app|icat1'on No.
`
`PCT{U S2009£05871 6
`
`Patent d:)cur11cI1t
`cited in search repon
`
`PI.Ib|iI.'a|liun
`darn:
`
`Pal::|1lfe|1ni|y
`n1o:1nbn:r($)
`
`PLIb11C«'Il10I1
`date
`
`JP 11-309183 A
`
`09.11.1999
`
`None
`
`US 6381779 81
`
`07.05.2002
`
`US 6678906 81
`1110 0309-24529-.1
`
`20.01.2004
`13. 11 .2003
`
`US 5817391 A1
`
`06. 10. 1998
`
`None
`
`US 5765241 A1
`
`16.06.1998
`
`AU 1997-12445 B2
`EP 0787451 A2
`EP 0787451 A3
`EP 0787451 81
`GB 2309638 A
`
`27.05.1999
`08.08. 1997
`13.10. 1999
`04.06.2003
`06.08.1997
`
`Form PCT.-"ISA.'210 (parent 1‘ami|_\-' annex) (July 2009)
`
`000805
`
`

`
`(12) INTERNATIONAL APPLICATION PUBLISHED UNDER THE PATENT COOPERATION TREATY {PCT}
`
`(l9) World Intellectual Property Organization
`International B1u'caL1
`
`(43) International Publication Date
`
`1 April 2010 (01.04.2010) (10) International Publication Number
`
`WO 2010/037082 A2
`
`(51)
`
`International Patent Classificatio-1|:
`D043 2?/14' [2U[)6.l']l]
`D030 If/tIl'E}(3[)(Jfi.[i1)
`
`{B1}
`
`(11)
`
`International Applicafiun Number:
`
`PCT.-’Ut33[)[)9."[l587 l 6
`
`(22)
`
`International Filing Date:
`29 September 3009 (29.09.2009)
`
`(25)
`
`Filing Language:
`
`English
`
`English
`
`US
`
`(26)
`
`(30)
`
`(71)
`
`(72)
`(75)
`
`Publication Language:
`
`Priority Data:
`6]r'lUl ,0-49
`29 Septeinber 2008 (29.09.2008)
`
`Applicant (fit? aft’ desigiinted States c=.rc'€pt' US): SHEEX
`L-LC [USFUS]; 169 Captain Lowman Road, Cliapin, SC‘
`29036 [US].
`
`Inventors; and
`Inventors.-‘Applicants ffoi‘ US omft=): WALVIUS, Susan.
`Katherine [USKUS]; I69 Captaiii Lowrnan Road, Chopin,
`SC 29030
`(US).
`}’I.-\RCl\'I:'\K..
`[\'liche]]e.. Nlarie
`[USIUS]; 169 Captain I_UW'l'l'l.i:l.11 Road, Chopin, SC 39036
`(US).
`
`(74)
`
`2%.; Trotilinan Sanders
`Agent: SCHNEIDER. Ryan.
`LLP, Bank of America Plaza, -600 Pcachtroe Street, NE,
`Suite 5200, Atlanta, GA 30308-2216 (US).
`
`Desigtlated States fttniess aI.I':e.i‘1.vt's'e .i'J?.t1".t'C'£T.t'C’C!',‘,i'rh)iP' einistfv
`kind afnarioncri p.rn.rec.'i'mt at-'m'i'afJi'£): Alf, AG, AL, AM,
`AU, AT, AU, AZ, BA, HI}, HU, HI], HR, I3“-’, HY, HZ,
`CA, CH, CL, CN, CO, CR, CU, CZ, DE, DK, DM, DO,
`DZ, EC, EE, EG, ES, FI, GB, GD, GE, GH, GM, GT,
`HN, HR, HU, ID, IL, IN, IS, JP, KE, KG, KM, KN, KP,
`KR, KZ, LA, LC, LK, LR, LS, LT, LU, LY, MA, MD,
`ME, MG. MK, MN, MW, MX,
`IVIY, MZ, NA, NG. NI,
`NO, NZ, OM, PE, PG, PH, PL, PT, RC), RS, RU, SC. SD,
`SE, SG, SK, SL, SM. ST, SV, SY, TJ, TM, TN, TR, TT,
`TZ, UA, UG, US, UZ, VC, VN, ZA, ZM, ZW'.
`
`(34)
`
`Designated States i_'um’ess oritenvisc iirdicwrred. for eve.~_1=
`fried qfregionnt’ _prorccrfon omfinbfe}: ARIPO {BW, GH,
`GM, KP, LS. MW, MZ, ‘NA, SD, SL, SZ, TZ. UG, ZM,
`ZW), Iitlrasialt {AM, AZ, BY, KG, KZ, Ml), RU, TJ,
`TM), European (AT, BE, BG, CH, CY, CZ, DE, DK, EE,
`ES, FI, FR, GB, GR, HR, HU, IE, IS, IT, LT, LU, LV,
`MC, MK, MT, NL, NO, PL, PT, RO, SE, SI, SK, SM,
`TR), OAPI (BF, BJ, CF, CG, CI, CM, GA, GN, GQ, GW,
`ML, MR, NE, SN, TD, TG).
`Published:
`
`wititotit interirrrtionaf s'erir'ci: report and to be repubffshetf
`upon receipt Qflhrtt report (Rim? 4r5'.2|{’g,i')
`
`(54) Title: FABRIC SYSTEM
`
`7
`
`-
`
`.. .
`
`.
`
`..
`
`.'
`
`..---’
`
`I
`
`I,‘
`
`»
`
`_._,
`
`\,
`
`(57) Abstract: Bedding material "including :1 tlrst fabric section manutac-
`tured fmin pcrfonnancc fabric and having a first and second side; and, a
`second fabric section attached to the first side of the first fabric section.
`
`Additionally, a. third fabric sectiml cam be attached to the second side Ul'.‘ll'.It:
`first fabric section. The first fabric section can be attached to the second
`fabric section through a [Iallock slilch. The iirst fabric section can include
`at first zone and a second zone wherein the first zone colilains diflierenl per-
`formanee properties from the second zone and the first zone can have ther-
`mal or moisture wicking properties.
`
`
`
`
`
`wo2010/037032A2||||||||||||||ll|||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
`
`338
`
`in
`
`
`!ll!1.!;!.*—*'1.'v.4[?.1i..l!.".!t.‘-|,!.J’!l[
`
`_
`
`_
`
`is
`
`flan
`
`000806
`
`
`
`
`
`
`
`

`
`W0 201l].r'l]3?'l]82
`
`l’CT;'US2D09f058'i'l 6
`
`FABRIC SYSTEM
`
`BACKGROUND OF THE INVENTION
`
`1.
`
`Field of the Invention
`
`The present invention relates generally to fabric systems, and more specifically to bed
`
`coverings constructed of high gauge circular knitted fabrics that accommodate and maintain
`
`optimum thermal conditions for sleep, which in turn can lead to faster sleep initiation and deeper,
`
`more restorative sleep.
`
`2.
`
`Description of Related Art
`
`Sleep p1'ob1ems in the United -States are remarkably widespread, affecting roughly three
`
`out of four American adults, according to research by the National Sleep Foundation (NSF).
`
`Consequently, a great deal of attention has been paid to the circumstances surrounding poor
`
`sleep, along with strategies for how to improve it.
`
`The implications are not merely academic. Sleep — not only the right amount of it but
`
`also the right quality — impacts not just day—to—day perfonnance, but also “the overall quality of
`1
`
`our lives,’ according to the NSF. Addressing the causes of poor quality sleep, therefore, has
`
`ramifications for millions.
`
`Though many factors contribute to sleep quality, the sleep environment itself plays a
`
`critical role, and sleep researchers routinely highlight temperature as one of the most important
`
`components in creating an environment for optimal sleep. As advised by the University of
`
`Maryland Medical Center, “a cool (not cold) bedroom is often the most conducive to sleep.” The
`
`National Sleep Foundation further notes that “temperatures above 75 degrees Fahrenheit and
`
`below 54 degrees will disrupt sleep," with 65 degrees being the ideal sleep temperature for most
`
`individuals, according to the NSF.
`
`A lower environmental
`
`temperature is not
`
`the only thermal factor associated with
`
`improved sleep. Researchers have noted a nightly drop in body temperature among healthy,
`
`normal adults during sleep. This natural cycle, when inhibited or not functioning properly, can
`
`disrupt sleep and delay sleep onset, according to medical researchers at Cornell University.
`
`Conversely, the researchers noted, a rapid decline in body temperature not only accelerates sleep
`
`onset but also “may facilitate an entry into the deeper stages of sleep.”
`
`000807
`
`

`
`W0 201l].r'l]3?'l]82
`
`l’CTlUS2D09f058":'l 6
`
`Therefore, maintaining an appropriately cool sleep environment and accommodating the
`
`body’s natural tendency to cool itself at night should be a top priority for individuals interested in
`
`optimizing their sleep quality. Performance fabrics crafted into bedding applications would be
`
`uniquely capable of promoting cool, comfortable — and therefore better — sleep, as these
`
`advanced fabrics maximize breathability and heat transfer. Peiformance fabrics are made for a
`
`variety of end—use applications, and can provide multiple functional qualities, such as moisture
`
`management, UV protection, anti—microbial, thermo—regu1ation, and windfwater resistance.
`
`There has been a long felt need in several industries to provide improved bedding to help
`
`individuals get better sleep. Such improved bedding would include beneficial wicking among
`
`other properties. For example, in marine, boating and recreational vehicle applications, bedding
`
`should resist moisture, fit odd—shaped mattresses and beds, and reduce mildew. Particularly with
`
`watercraft, there is a need to protect bedding, and specifically sheets, from moisture and mildew
`
`accumulation.
`
`An additional problem with bedding, notjust with marine and recreational vehicles, is the
`
`sticky, wet feeling that can occur when the bedding sheets are wet due to body sweat,
`
`environmental moisture, or other bodily fluids.
`
`In particular, when bedding is used during hot
`
`weather, or is continuously used for a long time by a person suffering from an illness, problems
`
`can arise in that the conventional bed sheet of cotton fiber or the like cannot sufficiently absorb
`
`the moisture. All of these issues lead to poor sleep.
`
`To date, performance fabric bedding products are not known. There are width limitations
`
`in the manufacturing of high gauge circular knit fabrics, because the finished width of bedding
`
`fabrics are dictated by the machine used in its construction. At present, performance fabrics are
`
`manufactured with a maximum width of under 90 inches wide, given present manufacturing and
`
`technical limitations, along with the inability of alternate manufacturing processes to produce a
`
`fabric with identical performance attributes. Yet, normal bed sheet panels can be 102 by 91
`
`inches or larger. Thus, perfonnance fabrics cannot yet be used for bed sheets.
`
`Some conventional solutions for the above issues that hinder a good night’s sleep include
`
`United States Patent 4,648,186, which discloses an absorbent wood pulp cellulose fiber that is
`
`provided in a variety of sizes and is placed under a mattress. The wood pulp is water absorbent
`
`and acts to capture moisture to prevent such moisture fi‘om being retained by the bedding or the
`
`2
`
`000808
`
`

`
`W0 201l].r'l]3?'l]82
`
`l’CTlUS2D09f058":'l 6
`
`bedding sheets. However,
`
`this proposed solution does not interact with the bedding or the
`
`bedding sheets, but merely acts as a sponge for moisture that is in proximity to the target bedding.
`
`United States Patent 5,092,088 discloses a sheet—like mat comprised of a mat cover, the
`
`inside of which is divided into a plurality of bag—like spaces, and a d1'yin g agent packed into a
`
`bag and contained in the bag-like spaces in such a manner that the drying agent cannot fall out of
`
`the bag-like spaces. A magnesium sulfate. a high polymer absorbent, a silica gel or the like can
`
`be used as the drying agent. As can be seen, this proposed solution to moisture in bedding is
`
`cumbersome and chemically-based.
`
`In the athletic apparel
`
`industry, moisture wicking fabric has been used to construct
`
`athletic apparel.
`
`For example, United States Patent 5,636,380 discloses a base fabric of
`
`CoolmaxQ high moisture evaporation fabric having one or more insulating panels of ThermaxB
`
`or TherrnastatQ hollow core fiber fabric having moisture wicking capability and applied to the
`
`inner side of the garment for skin contact at selected areas of the body where muscle protection
`
`is desired. However, this application cannot be applied to bedding sheets due to the limitations
`
`of the size of the performance fabrics manufactured. Further, performance fabric such as this
`
`type cannot be easily stitched together as the denier is so fine that stitching this fabric results in
`
`the stitching simply falling apart.
`
`Circular knitting is typically used for athletic apparel, The process includes circularly
`
`knitting yarns into fabrics. Circular knitting is a form of weft knitting where the knitting needles
`
`are organized into a circular knitting bed. A cylinder rotates and interacts with a cam to move
`
`the needles reciprocally for knitting action. The yarns to be knitted are fed from packages to a
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`carrier plate that directs the yarn strands to the needles. The circular fabric emerges from the
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`knitting needles in a tubular form through the center of the cylinder. This process is described in
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`United States Patent 7,117,695. However, the machinery presently available for this method of
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`manufacture can only produce a fabric with a maximum width of approximately 90 inches.
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`Therefore,
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`this process has not been known to manufacture sheets, since sheets can have
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`dimensions of 91 inches by 102 inches or greater.
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`Further, the machinery that is used for bedding is very different than for athletic wear.
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`For example, bedding manufacturing equipment is not equipped to sew flatlock stitching or to
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`provide circular knitting. Bed sheets typically are knit using a process known as warp knitting, a
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`process capable of producing finished fabrics in the widths required for bedding. This method,
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`however, cannot be employed to produce high-quality performance fabrics. Warp knitting is not
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`capable of reproducing these fabrics’
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`tine tactile qualities nor their ornni-direction stretch
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`properties, for example.
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`Circular knitting must be employed to produce a perfontnance fabric that retains these
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`fabric’s full range of benefits and advantages. However,
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`in order to produce a fabric of the
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`proper width for bedding applications, a circular knit machine of at least 48 inches in diameter
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`would be necessary. Manufacturing limitations
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`therefore preclude the construction of
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`performance fabrics at proper widths for bedding. The industry is unsure if it could actually knit
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`and then finish performance fabrics at these large sizes, even if the machinery were readily
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`available.
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`Further, athletic sewing factories a1'e typically not equipped to sew and handle large
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`pieces of fabrics so that equipment limitations do not allow for the manufacture of bedding
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`sheets.
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`What is needed, therefore, is a bedding system that utilizes performance fabrics and their
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`beneficial properties__ the design of which acknowledges and addresses limitations in the
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`manufacture of these fabrics.
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`It
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`is to such a system that the present invention is primarily
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`di rec ted.
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`BRIEF SIIMMARY OF THE INVENTION
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`Briefly described, in preferred form, the present invention is a high gauge circular knit
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`fabric for use in bedding. and a method for manufacturing such bedding. The bedding fabric has
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`superior performance properties, while allowing for manufacture by machinery presently
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`available and in use.
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`ln order to achieve a finished width of the size needed to create sheet—sized
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`performance fabric, a high gauge circular knit machine of at least 48 inches in diameter is
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`necessary. And while warp knitting machines are available that can produce wider fabrics, this
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`method will not provide a fabric with the tactile qualities required, nor provide a fabric with
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`omni—directional stretch.
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`In an exemplary embodiment, the present invention is a method of making a finished
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`fabric comprising at least two discrete perfonnance fabric portions, and joining at least two
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`discrete performance fabric portions to form the finished fabric.
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`Forming the at least two
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`discrete performance fabric portions can comprise knitting at least two discrete performance
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`fabric portions, and more preferably, circular knitting at least two discrete performance fabric
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`portions. Joining the at least two discrete performance fabric portions to form the finished fabric
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`can comprise stitching at least two discrete performance fabric portions together to form the
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`finished fabric.
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`The at
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`least
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`two discrete performance fabric portions can have different
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`fabric
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`characteristics.
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`Fabric characteristics as used herein include, among other things, moisture
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`management, UV protection, anti—microbial,
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`thermo—regulation, wind resistance and water
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`nesistance.
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`The finished fabric can be used in, among other applications, residential settings, or in
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`marine, boating and recreational vehicle environments.
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`The present sheets offer enhanced drape and comfort compared to traditional cotton
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`bedding, and are as fine as silk, yet provide the benefits of high elasticity and recovery along
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`with superior breathability, body-heat
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`transport, and moisture management as compared to
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`traditional cotton bedding.
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`Conventional fitted sheets can bunch and slide on standard mattress sizes. Furthermore,
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`if the fitted bed sheets do not fit properly, they do not provide a smooth surface to lie on. The
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`present invention overcomes these issues.
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`The present high gauge circular knit fabrics stretch to fit and offer superior recovery on
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`the mattress allowing the fabric to conform to fit the mattress without popping off the corners of
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`the mattress or billowing. The performance fabric can include spandex, offers a better fit than
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`conventional bedding products, can accommodate larger or smaller mattress sizes with a single
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`size sheet, and can conform to mattresses with various odd dimensions.
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`Spandex — or elastane — is a synthetic fiber known for its exceptional elasticity.
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`It is
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`stronger and more durable than rubber, its major non—synthetic competitor.
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`lt is a polyurethane-
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`polyurea copolymer that was invented by DuPont. “Spandex” is a generic name, and an anagram
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`of the word “expands.”
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`“Spandex"’ is the preferred name in North America; elsewhere it
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`is
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`2
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`referred to as “elastane.’ The most famous brand name associated with spandex is Lycra, a
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`trademark of Invista.
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`The present high gauge circular knit fabric offers durability in reduced pilling and pulling
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`when compaied to other knit
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`technologies. and offer reduced wrinkles and enhanced color
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`steadfastness
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`In a preferred embodiment. the present pe1'forn1ance fabric can allow for a one—size fitted
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`sheet that can actually fit two different size mattresses. For example, the full fitted sheet of the
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`present invention can fit on both the full and queen size bed. The twin fitted sheet of the present
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`invention will also fit an XL twin.
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`In a boating application, the present
`
`invention can be
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`produced to fit almost every custom boat mattress.
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`Testing of the present
`
`invention conducted at
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`the North Carolina State University
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`(NCSU) Center for Research on Textile Protection and Comfort confirms that
`
`the present
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`performance fabrics provide a cooler sleeping environment than cotton. Performance bedding
`
`was tested side-by-side with commeicially available cotton bed sheets in a series of procedures
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`designed to measure each product’s heat- and moisture-transport properties, as well as
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`warmfcool-to-touch thermal transport capabilities.
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`Across all
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`tests,
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`the present performance fabrics in bedding outperformed cotton.
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`demonstrating the performance fabric’s superiority in establishing and maintaining thermal
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`comfort during sleep. This advantage is evident to users from the very onset, as NCSU testing
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`indicates that, on average, performance bedding of the present invention offers improved heat
`
`transfer upon initial contact with the skin, resulting in a cooler-to-the-touch feeling.
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`During sleep, high gauge circular knit performance bedding of the present invention
`
`helps to maintain thermal comfort by trapping less body heat and breathing better than cotton.
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`Testing has demonstrated that performance bedding made out of performance fabrics transfers
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`heat away from the body up to two times more effectively than cotton. This is critically
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`important not only for sustained comfort during sleep, but also in terms of enabling the body to
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`cool itself as rapidly as possible to facilitate sleep onset.
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`In addition to trapping less heat,
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`performance bedding breathes better than cotton — up to 50% better, giving performance bedding
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`a strong advantage in terms of ventilation and heat and moisture transfer.
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`The performance advantage over cotton holds true for simulated dry and wet skin
`
`conditions, confirming that certain performance fabrics in bedding are better suited than cotton at
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`managing moisture (_e.g., sweat) to maintain thermal comfort.
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`In addition to wicking moisture
`
`away from the skin through capillary action,
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`the performance fabric’s advanced breathability
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`fu1'ther enables heat and moisture transfer through evaporative cooling. As a result, the user is
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`kept cooler, drier and more comfortable than with cotton.
`
`The present performance bedding holds a distinct advantage over cotton in enabling,
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`accommodating and maintaining optimum thermal conditions for sleep, which in turn can lead to
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`faster sleep initiation and deeper, more restorative sleep.
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`These and other objects, features and advantages of the present invention will become
`
`more apparent upon reading the following specification in conjunction with the accompanying
`
`drawings.
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`BRIEF DESCRIPTION OF THE FIGURES
`
`Fig. 1 illustrates a preferred embodiment of the present invention.
`
`Fig. 2 illustrates another preferred embodiment of the present invention.
`
`Fig. 3 illustrates a further preferred embodiment of the present invention.
`
`Fig. 4 illustrates another preferred embodiment of the present invention.
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`DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
`
`Although preferred embodiments of the invention are explained in detail, it is to be
`
`understood that other embodiments are contemplated. Accordingly, it is not intended that the
`
`invention is limited in its scope to the details of construction and arrangement of components set
`
`forth in the following description or illustrated in the drawings. The invention is capable of other
`
`embodiments and of being practiced or carried out in various ways. Also, in describing the
`
`preferred embodiments, specific terminology will be resorted to for the sake of clarity.
`
`It must also be noted that, as used in the specification and the appended claims, the
`9!
`id
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`singular forms “a,
`
`an” and “the” include plural referents unless the context clearly dictates
`
`otherwise.
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`For example, reference to a sheet or portion is intended also to include the
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`manufacturing of a plurality of sheets or portions. References to a sheet containing “a”
`
`constituent is intended to include other constituents in addition to the one named.
`
`Also, in describing the preferred embodiments, terminology will be resorted to for the
`
`sake of clarity.
`
`It is intended that each term contemplates its broadest meaning as understood by
`
`those skilled in the art and includes all technical equivalents which operate in a similar manner to
`
`accomplish a similar purpose.
`
`Ranges may be expressed herein as f1'om “about" or “approximately” one particular value
`
`andfor to “about” or “approximately” another particular value. When such a range is expressed,
`
`another embodiment includes from the one particular value andfor to the other particular value.
`
`By “comprising” or “containing” or "including" is meant
`
`that at
`
`least
`
`the named
`
`compound, element, particle, or method step is present in the composition or article or method,
`
`but does not exclude the presence of other compounds, materials, panicles, method steps, even if
`
`the other such compounds, material, particles, method steps have the same function as what is
`
`named.
`
`It
`
`is also to be understood that the mention of one or more method steps does not
`
`preclude the presence of additional method steps or intervening method steps between those
`
`steps expressly identified. Similarly, it is also to be understood that the mention of one or more
`
`components in a fabric or system does not preclude the presence of additional components or
`
`intervening components between those components expressly identified.
`
`Referring now in detail to the drawing figures, wherein like reference numerals represent
`
`like parts throughout the several views. the present invention of Figs. 1 and 4 provides a sheet
`
`10 shown having dimensions of 102 inches in length and 91 inches in width. The material is
`
`manufactured f1'om performance fabric, which can include, for example. varying amounts of one
`
`or more of Lycra, Coolmax, Thermax and Thermastat.
`
`In a preferred embodiment. the fabric is
`
`treated so that the fabric has antimicrobial properties. By using circular-knit performance fabric,
`
`the fabric is able to provide elasticity in all four directions. This property allows for the sheet to
`
`tit extraordinary mattress, cushion and bedding shapes, as well as providing better fits for
`
`traditional rectangular sheets. By using performance fabrics, the sheet has elastic properties that
`
`allow stretching in the directions shown as 30.
`
`In addition, by using circular-knit performance
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`fabric, the resulting bedding retains an exceptionally fine tactile quality critical for providing
`
`maximum levels of enhanced comfort.
`
`An alternative to circular knitting is non—circular knitting — for example, warp knitting.
`
`This method can achieve widths greater than circular knitting. Industrial warp knit machines. for
`
`example, can produce tricote warp knit fabrics up to 130-140 inches in width. Circular knitting,
`
`however, is less expensive, as it requires less set-up time. Circular knitting also provides greater
`
`multidirectional stretch.
`
`In order to provide a sheet that exceeds the maximum dimensions of fabric that can be
`
`produced by available circular knitting machines, flat lock stitching 12 is used to join a plurality
`
`of portions resulting in a sheet that is 91 inches wide (as shown).
`
`In an exemplary embodiment,
`
`piping 11 can be included in close proximity to the stitching. The stitching can be the same color
`
`as the fabric of the sheet portions, or different color(s). The piping can be 3.34 inch straight
`
`piping without a cord or other filler.
`
`In one preferred embodiment, the stitching is 16 stitches per
`
`inch. Piping 11 can be included at one end of the sheet and can be the same or a different color
`
`as the sheet fabric.
`
`For a fitted sheet, the sheet can include an elastic portion surrounding the edge of the
`
`fitted shee