W0 201 I].-"03 7082
`
`PCTa'US2Dl]9f0587l 6
`
`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—circu]ar 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.
`
`l.n 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 H 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 surrottnding the edge of the
`
`fitted sheet to better keep the fitted sheet in place when placed on a mattress or other sleeping
`
`surface. A cord can be sewn into the edge of the fitted sheet and cinched around the mattress or
`
`other sleeping surface to better hold the fitted sheet in place.
`
`Referring to Fig. 2, a sheet i.s shown having dimensions of9l inches wide and 102 i.nches
`
`in length.
`
`In this embodiment, stitching 14 is shown 34 inches from an interior edge 13 of a
`
`main portion 16 and another stitch 14 at edge 2|] of the sewn-on portion. Flat lock stitching can
`
`be used for the stitching. Piping can be applied at or in proximity to the stitching.
`
`Referring to Fig. 3, a non-rectangular shaped sheet
`
`is shown.
`
`In this exemplary
`
`embodiment, elastic can be included around the edge of the fitted sheet to better maintain the
`
`fitted sheet in position when placed on a sleeping surface.
`
`In one embodiment, pull ties 24 can
`
`be installed at various locations around the edge of the fitted sheet
`
`in order to assist
`
`in
`
`maintaining the fitted sheet secured to the sleeping surface. The pull tie can be cinched to
`
`increase tension around the edge of the fitted sheet as shown by 26.
`
`9
`000976
`
`BEDGEAR 1008 (part 11)
`IPR of U.S. Pat. No. 8,402,580
`
`

`
`W0 201l].r'l]3?'l]82
`
`l’CT;'US2D09f058'i'l 6
`
`Stitching used for securing the portions of the sheet together can include that shown as
`
`233.
`
`In another embodiment, the stitching used for securing the portion of fabric together is
`
`shown as 28b.
`
`Referring to Fig. 4, yet another preferred embodiment of the invention is shown.
`
`In this
`
`embodiment, the sheet can be assembled through stitching of differing fabrics for generating
`
`performance zones in the sheet. For example, zone 32 can have higher wicking properties than
`
`the other zones since this area is where the majority of the individual body rests. Areas 343
`
`through 344:! can have higher spandex or other elastic fabric properties so that the fit around a
`
`sleeping surface is improved. Area 36 may have thermal properties such as increased cooling
`
`since this area is generally where the individual’s head lies.
`
`In an exemplary embodiment, the
`
`pillow covers of pillows used by the individual also have differing properties from the remainder
`
`of the sheet, e.g., thermal properties.
`
`The present
`
`invention encompasses the construction of bedding materials that have
`
`superior performance properties while allowing for manufacture by machinery presently
`
`available and in use. More specifically, the invention is related to a new method for fabricating a
`
`covering and or sheets in bedding. When using the circular knitting machine, the high gauge
`
`performance fabrics can only be made to a maximum size of 72.5 inches without losing the
`
`integrity of the spandex in the fabric. Yet, normal sheet panels are 102 X 91 inches. This
`
`presents problems when manufacturing sheets from performance fabrics.
`
`Additionally, special stitching techniques must be used given the thread density of the
`
`fabric. Using this special stitching, panels are sewn together to produce bedding or a sheet that is
`
`the proper size for standard bed sheets. Because discrete portionsfpanels are used in the
`
`manufacture of the present fabrics. panels can be selected that provide different properties for
`
`different areas of the bedding (Fig. 4). Stitching or seams on the sheet can also allow for the
`
`ease of making the bed. Because the bedding is made from performance fabric with spandex, it
`
`stretches to permit multiple and custom sizing for applications in cribs, recreational vehicles and
`
`boats.
`
`Circular knitting machines used for high gauge performance bedding fabrics are called
`
`high—gauge circular knitting machines, because of dense knitting with thin yarn. High gauge
`
`generally denotes 17 gauges or more. Seventeen gauges indicate that 1'? or more cylinder
`
`10
`
`000977
`
`

`
`W0 201l].r'l]3?'l]82
`
`l’CTlUS2D09f058":'l 6
`
`needles are contained in one inch. Circular knitting machines of less than 17 gauges are referred
`
`to as low-gauge circular knitting machines. The low-gauge circular knitting machines are often
`
`used to knit outelwear.
`
`“Yarn count” indicates the linear density ("yarn diameter or fineness) to which that
`
`particular yarn has been spun. The choice of yarn count is restricted by the type of knitting
`
`machine employed and the knitting construction. The yarn count, in turn, influences the cost,
`
`weight, opacity, hand and drape of the resulting knitted structure.
`
`In general, staple spun yarns
`
`tend to be comparatively more expensive the finer their count, because finer fibers and a more
`
`exacting spinning process are necessary in order to prevent the yarn from showing an irregular
`
`appearance.
`
`A top width in the 90-inch range is currently possible using a circular knit fabric formed
`
`on a 36-38-inch diameter machine, although higher levels of spandex in the performance fabric
`
`tend to pull the width in. In just one example, on a 30-inch diameter machine, the spandex can
`
`reduce an otherwise 94-inch circumference fabric tube to one with a 60-65 inch finished width.
`
`A major limitation in finished width is not strictly a knitting concern but also concerns
`
`finishing. With performance fabric, it tends to sag in the middle — increasingly so with greater
`
`widths — making finishing difficult to impossible above a certain threshold. A possible 90-inch
`
`finished width is contingent upon having a good finishing set—up capable of handling the present
`
`performance fabric, This potential for difficulties would only become compounded at the larger
`
`widths required for bed sheets.
`
`In a preferred process.
`
`the present fabric undergoes a heat setting finishing process.
`
`Applying a moisture-wicking finish to another fabric — like cotton — that can be produced at
`
`larger widths appears unlikely to match the moisture-control properties of the present fabric, as
`
`polyester itself is naturally moisture-resistant and there are physical actions (eg. capillary action)
`
`at play. Further,
`
`the use of cotton comes at the expense of bneathability and heat—transfer
`
`capabilities (as confirmed by laboratory testing) and stnetchability.
`
`Numerous characteristics and advantages have been set forth in the foregoing description,
`
`together with details of structure and function. While the invention has been disclosed in several
`
`forms,
`
`it will be apparent to those skilled in the art that many modifications, additions, and
`
`deletions, especially in matters of shape, size, and arrangement of parts, can be made therein
`
`11
`
`000978
`
`

`
`W0 201l].r'l]3?'l]82
`
`l’CTlUS2D09f058":'l 6
`
`without departing from the spirit and scope of the invention and its equivalents as set foith in the
`
`following claims. Therefore, other modifications or embodinients as may be suggested by the
`
`teachings herein are particularly reserved as they fall within the breadth and scope of the claims
`
`here appended.
`
`12
`
`000979
`
`

`
`W0 201l].r'l]3?'l]82
`
`l’CTlUS2D09f058":'l 6
`
`What is claimed is‘.
`
`CLAIMS
`
`1.
`
`A method of making a finished fabric at least 90 inches wide comprising:
`
`forming at least two discrete performance fabric portions; and
`
`joining at least two discrete performance fabric portions to form the finished fabric.
`
`2.
`
`The method according to Claim 1, wherein forming at least two discrete performance
`
`fabric portions comprises knitting at least two discrete performance fabric portions.
`
`3.
`
`The method according to Claim 1. wherein forming at least two discrete performance
`
`fabric portions comprises circular knitting at least two discrete performance fabric portions.
`
`4.
`
`The method according to Claim 1, wherein joining at least two discrete performance
`
`fabric portions to form the finished fabric comprises stitching at least two discrete performance
`
`fabric portions together to form the finished fabric.
`
`5.
`
`A method of making a finished fabric at least 90 inches wide comprising:
`
`circular knitting at least two discrete performance fabric poitions; and
`
`stitching at least two discrete performance fabric portions together to t'orm the finished
`
`fabric.
`
`6.
`
`7'.
`
`fabric.
`
`The method according to Claim 5, wherein the finished fabric comprises a bed sheet.
`
`The method according to Claim 5, further comprising heat setting finishing the finished
`
`8.
`
`The method according to Claim 5. further comprising providing piping to the finished
`
`fabric.
`
`9.
`
`A method of making a bed sheet at
`
`least 90 inches wide from performance fabric
`
`comprising:
`
`circular knitting at least two discrete performance fabric portions;
`
`stitching at least two discrete performance fabric portions together; and
`
`13
`
`000980
`
`

`
`W0 2010.-'l]3?'l]82
`
`PCTfUS2009.I'058716
`
`heat setting finishing the stitched at least two discrete performance fabric portions to
`
`form the finished bed sheet.
`
`10.
`
`The method according to Claim 9. further comprising providing piping to the finished
`
`bed sheet.
`
`11.
`
`The method according to Claim 9, wherein the at least two discrete performance fabric
`
`portions have different fabric characte1'istics.
`
`12.
`
`The method according to Claim 11, wherein fabric characteristics are selected from the
`
`group consisting of moisture management, UV protection, anti-microbial,
`
`thermo-regulation,
`
`wind resistance and water nesistance.
`
`13.
`
`A finished fabric at least 90 inches wide comprising:
`
`a first circular knitted performance fabric; and
`
`a second circular knitted performance fabric;
`
`wherein the first and second performance fabrics are discrete; and
`
`wherein the first and second performance fabrics are joined to form the finished fabric.
`
`14.
`
`The finished fabric of Claim 13, wherein the finished fabric comprises a bed sheet.
`
`15.
`
`The finished fabric of Claim 13, fu1'ther comprising piping.
`
`16.
`
`The finished fabric of Claim 13, wherein the first and second performance fabrics have
`
`different fabric characteristics.
`
`17.
`
`The finished fabric of Claim 16, wherein fabric characteristics are selected from the
`
`group consisting of moisture management, UV protection, anti—microbia1,
`
`thermo—regulation,
`
`wind resistance and water nesistance.
`
`14
`
`000981
`
`

`
`W0 20103037082
`
`l’CT:'US2009:'0587l6
`
`1:'4
`
`bu.
`
`E
`
`
`
`.§,.m§.umcne...
`
`000982
`
`

`
`W0 20103037082
`
`PCTfUS2009J'058'?16
`
`ZI4
`
`
`
`000983
`
`

`
`W0 201l].r'l]3?'l]82
`
`l’CTlUS20l]9'!058":'16
`
`3H
`
`22
`
`
`
`;
`
`::”fifi$H%Jfi&§Hfi:
`-; f1‘*i
`
`-
`
`:.-\e..
`3..
`
`_
`
`"
`
`-M3;
`
`000984
`
`

`
`W0 20ll].r'l]3?'l]82
`
`PCTlUS20l]9!058';'16
`
`4!-1
`
`34b
`
`-.n-..\- -\-m-m-..-.-..-.-..-m .-..-m-m-...-..n.. m m 111 m ..
`
`-:
`
`32
`
`
`
`%34d
`
`.. ._. ._. ... ._. ._. ._. ... ._. ._. ._. ... . .. . .. . .. . .. . .. ._. . . . . .. . .... .........................,....................................... ...................... .... ............. ,... ..... . . .. ._. .. . .
`
`
`
`34$
`-4-
`
`000985
`
`

`
`(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
`
`000986
`
`
`
`
`
`
`
`

`
`WO 2010/037082 A3 ||||||||||||||||||I||||||||I|||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||I|
`
`(88) Date of puhlicatiun 0f the international search report:
`8 J L11); 2010
`
`000987
`
`

`
`
`
`
`
`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 7»'t]'5: 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 l0O10l-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 O6 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)
`
`000988
`
`

`
`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)
`
`000989
`
`

`
` (19)
`
`JAPANESE PATENT OFFICE
`
`PATENT ABSTRACTS OF JAPAN
`
`(11) Pubiicafian nurrhar: 11309133 A
`
`(4-3) Date of publcaticn cf application:
`
`09.11.59
`
`(51) Int. cl
`
`A516 ‘"95
`
`A476 SIDE
`
`B323 5126
`
`DOGM 17i'0D
`
`(21) Appllcaiien number:
`
`10132735
`
`(71) Nxhilcant
`
`MORIIICHI KYU KK
`
`(22) Date affiina: 27.04.98
`
`(72) Inventor:
`
`MATSUMOTO TAKESHI
`
`(54) WATERPROOF SHEET
`
`(5?) Abstract
`
`'fi|:Hs such as polyester and e warp-knit
`cf syrriheii:
`fabric such as raschal or tricci are used singuiariy or
`in larnhatinn.
`
`COPYRIGHT: (C-.'i1999.JPO
`
`I131? T111131 IZJTSISIA I312
`
`
`
`
`_,
`
`
`
`5&2“
`L
`
`.
`
`A
`
`‘I
`
`PROBLEM TO BE SOLVED: To make urine and sweat
`
`and
`clI:rt|1ee
`bedcing,
`prevent
`‘ii:
`and
`absorbed
`a
`by
`uehg
`stained
`being
`from
`surrounding
`texture
`for a
`cifi'L.reive
`w.Iter-perr11eai:.Ie md w:1:er-
`surfaw fabric, ung a water-imperrmabia
`and s'r-
`perrnfile iiex'h..re by water-repeli.-.nt
`finhirg fur
`a
`back Tsbric. and arranging an Intermediate ‘Fabric having
`a water absorbing property and prevenfng the bacicflow
`oi ma-|s1:LIra baiwa-an both iabrics.
`
`SOLUTION: A knit fabric or a woven fabric made of a
`
`'i:ex'i:ure, preferably
`w.Ii:er-penneable and w'ai:er-i:i'ri‘|‘I.Ieive
`polyester or other eyniheiic fibers, and having a proper
`expensicnlshrinkage prcperty is used fur
`a
`surface
`fabric 1
`tc be kept
`in direct contact with ‘line 5|(i'l. A
`knit
`fabric
`or
`a wcven
`fabric made
`of
`a
`
`by
`texture
`a'r-permeable
`and
`water-imperrneabie
`water-repellent
`finishing, preferably pclyester or ether
`synihetlc iibere,
`is used for a back fabric 2 to be kept
`in ccntact wiih the matiress cf beddirg. A ncnwcven
`fabric
`or
`a
`knit
`fabric
`having
`a water absorbing
`property and havirg ‘the required ihickneee to prevent
`the baci-ciiow oi’ absorbed moistme
`is used for an
`
`intermediate fabric 3. and preferably a ncnwcven fabric
`
`-1.
`
`000990
`
`

`
`(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
`
`000991
`
`
`
`
`
`
`
`

`
`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.”
`
`000992
`
`

`
`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
`
`000993
`
`

`
`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
`
`carrier plate that directs the yarn strands to the needles. The circular fabric emerges from the
`
`knitting needles in a tubular form through the center of the cylinder. This process is described in
`
`United States Patent 7,117,695. However, the machinery presently available for this method of
`
`manufacture can only produce a fabric with a maximum width of approximately 90 inches.
`
`Therefore,
`
`this process has not been known to manufacture sheets, since sheets can have
`
`dimensions of 91 inches by 102 inches or greater.
`
`Further, the machinery that is used for bedding is very different than for athletic wear.
`
`For example, bedding manufacturing equipment is not equipped to