`International Bureau
`
`(12) INTERNATIONAL APPLICATION PUBLISHED UNDER THE PATENT COOPERATION TREATY (PCT)
`1 11111 1111E11 II 111111 11111 11111 11111 I 1111 II III 11111 0 01 11 III 11111 001 1111 1111101111 11111111
`(10) International Publication Number
`WO 2010/037082 A2
`
`(43) International Publication Date
`1 April 2010 (01.04.2010)
`
`PCT
`
`(51) International Patent Classification:
`D04B 21/14 (2006.01) (cid:9)
`DO3D 11/00 (2006.01)
`(21) International Application Number:
`PCT/US2009/058716
`
`(22) International Filing Date:
`29 September 2009 (29.09.2009)
`
`English
`
`English
`
`(25) Filing Language: (cid:9)
`(26) Publication Language: (cid:9)
`(30) Priority Data:
`61/101,049 29 September 2008 (29.09.2008) (cid:9)
`US
`(71) Applicant (for all designated States except US): SHEEX
`LLC [US/US]; 169 Captain Lowman Road, Chapin, SC
`29036 (US).
`(72) Inventors; and
`(75) Inventors/Applicants (for US only): WALVIUS, Susan,
`Katherine [US/US]; 169 Captain Lowman Road, Chapin,
`SC 29036 (US). MARCINIAK, Michelle, Marie
`[US/US]; 169 Captain Lowman Road, Chapin, SC 29036
`(US).
`(74) Agent: SCHNEIDER, Ryan, A.; Troutman Sanders
`LLP, Bank of America Plaza, 600 Peachtree Street, N.E.,
`Suite 5200, Atlanta, GA 30308-2216 (US).
`
`(81) Designated States (unless otherwise indicated, for every
`kind of national protection available): AE, AG, AL, AM,
`AO, AT, AU, AZ, BA, BR, BG, RH, BR, 13W, BY, 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, MY, MZ, NA, NG, NI,
`NO, NZ, OM, PE, PG, PH, PL, PT, RO, 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.
`(84) Designated States (unless otherwise indicated, for every
`kind of regional protection available): ARIPO (BW, GH,
`GM, KE, LS, MW, MZ, NA, SD, SL, SZ, TZ, UG, ZM,
`ZW), Eurasian (AM, AZ, BY, KG, KZ, MD, 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, 13J, CF, CG, CI, CM, GA, ON, GQ, GW,
`ML, MR, NE, SN, TD, TG).
`Published:
`without international search report and to he republished
`upon receipt of that report (Rule 48.2(g))
`
`(54) Title: FABRIC SYSTEM
`
`(57) Abstract: Bedding material including a first fabric section manufac-
`tured from performance 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 section can be attached to the second side of the
`first fabric section. The first fabric section can be attached to the second
`fabric section through a flatlock stitch. The first fabric section can include
`a first zone and a second zone wherein the first zone contains different per-
`formance properties from the second zone and the first zone can have ther-
`mal or moisture wicking properties.
`
`WO 2010/037082 A2
`
`000318
`
`BEDGEAR 1024 (part 4)
`IPR of U.S. Pat. No. 8,402,580
`
`
`
`WO 2010/037082 (cid:9)
`
`PCT/US2009/058716
`
`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 problems 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 performance, but also "the overall quality of
`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."
`
`1
`
`000319
`
`
`
`WO 2010/037082 (cid:9)
`
`PCT/US2009/058716
`
`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. Performance 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-regulation, and wind/water 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, not just 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, performance 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 from being retained by the bedding or the
`
`2
`
`000320
`
`
`
`WO 2010/037082 (cid:9)
`
`PCT/US2009/058716
`
`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 drying 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 ThermastatQ 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 sew flatlock stitching or to
`provide circular knitting. Bed sheets typically are knit using a process known as warp knitting, a
`
`3
`
`000321
`
`
`
`WO 2010/037082 (cid:9)
`
`PCT/US2009/058716
`
`process capable of producing finished fabrics in the widths required for bedding. This method,
`however, cannot be employed to produce high-quality performance fabrics. Warp knitting is not
`capable of reproducing these fabrics' fine tactile qualities nor their omni-direction stretch
`properties, for example.
`
`Circular knitting must be employed to produce a performance fabric that retains these
`fabric's full range of benefits and advantages. However, in order to produce a fabric of the
`proper width for bedding applications, a circular knit machine of at least 48 inches in diameter
`would be necessary. Manufacturing limitations therefore preclude the construction of
`performance fabrics at proper widths for bedding. The industry is unsure if it could actually knit
`and then finish performance fabrics at these large sizes, even if the machinery were readily
`available.
`
`Further, athletic sewing factories are typically not equipped to sew and handle large
`pieces of fabrics so that equipment limitations do not allow for the manufacture of bedding
`sheets.
`
`What is needed, therefore, is a bedding system that utilizes performance fabrics and their
`beneficial properties, the design of which acknowledges and addresses limitations in the
`manufacture of these fabrics. It is to such a system that the present invention is primarily
`directed.
`
`BRIEF SUMMARY OF THE INVENTION
`
`Briefly described, in preferred form, the present invention is a high gauge circular knit
`fabric for use in bedding, and a method for manufacturing such bedding. The bedding fabric has
`superior performance properties, while allowing for manufacture by machinery presently
`available and in use. In order to achieve a finished width of the size needed to create sheet-sized
`performance fabric, a high gauge circular knit machine of at least 48 inches in diameter is
`necessary. And while warp knitting machines are available that can produce wider fabrics, this
`method will not provide a fabric with the tactile qualities required, nor provide a fabric with
`omni-directional stretch.
`
`In an exemplary embodiment, the present invention is a method of making a finished
`fabric comprising at least two discrete performance fabric portions, and joining at least two
`
`4
`
`000322
`
`
`
`WO 2010/037082 (cid:9)
`
`PCT/US2009/058716
`
`discrete performance fabric portions to form the finished fabric. Forming the at least two
`discrete performance fabric portions can comprise knitting at least two discrete performance
`fabric portions, and more preferably, circular knitting at least two discrete performance fabric
`portions. Joining the at least two discrete performance fabric portions to form the finished fabric
`can comprise stitching at least two discrete performance fabric portions together to form the
`finished fabric.
`
`The at least two discrete performance fabric portions can have different fabric
`characteristics. Fabric characteristics as used herein include, among other things, moisture
`management, UV protection, anti-microbial, thermo-regulation, wind resistance and water
`resistance.
`
`The finished fabric can be used in, among other applications, residential settings, or in
`marine, boating and recreational vehicle environments.
`
`The present sheets offer enhanced drape and comfort compared to traditional cotton
`bedding, and are as fine as silk, yet provide the benefits of high elasticity and recovery along
`with superior breathability, body-heat transport, and moisture management as compared to
`traditional cotton bedding.
`
`Conventional fitted sheets can bunch and slide on standard mattress sizes. Furthermore,
`if the fitted bed sheets do not fit properly, they do not provide a smooth surface to lie on. The
`present invention overcomes these issues.
`
`The present high gauge circular knit fabrics stretch to fit and offer superior recovery on
`the mattress allowing the fabric to conform to fit the mattress without popping off the corners of
`the mattress or billowing. The performance fabric can include spandex, offers a better fit than
`conventional bedding products, can accommodate larger or smaller mattress sizes with a single
`size sheet, and can conform to mattresses with various odd dimensions.
`
`Spandex - or elastane - is a synthetic fiber known for its exceptional elasticity. It is
`stronger and more durable than rubber, its major non-synthetic competitor. It is a polyurethane-
`polyurea copolymer that was invented by DuPont. "Spandex" is a generic name, and an anagram
`of the word "expands." "Spandex" is the preferred name in North America; elsewhere it is
`
`5
`
`000323
`
`
`
`WO 2010/037082 (cid:9)
`
`PCT/US2009/058716
`
`referred to as "elastane." The most famous brand name associated with spandex is Lycra, a
`trademark of Invista.
`
`The present high gauge circular knit fabric offers durability in reduced pilling and pulling
`when compared to other knit technologies, and offer reduced wrinkles and enhanced color
`steadfastness
`
`In a preferred embodiment, the present performance fabric can allow for a one-size fitted
`sheet that can actually fit two different size mattresses. For example, the full fitted sheet of the
`present invention can fit on both the full and queen size bed. The twin fitted sheet of the present
`invention will also fit an XL twin. In a boating application, the present invention can be
`produced to fit almost every custom boat mattress.
`
`Testing of the present invention conducted at the North Carolina State University
`(NCSU) Center for Research on Textile Protection and Comfort confirms that the present
`performance fabrics provide a cooler sleeping environment than cotton. Performance bedding
`was tested side-by-side with commercially available cotton bed sheets in a series of procedures
`designed to measure each product's heat- and moisture-transport properties, as well as
`warm/cool-to-touch thermal transport capabilities.
`
`Across all tests, the present performance fabrics in bedding outperformed cotton,
`demonstrating the performance fabric's superiority in establishing and maintaining thermal
`comfort during sleep. This advantage is evident to users from the very onset, as NCSU testing
`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.
`
`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.
`Testing has demonstrated that performance bedding made out of performance fabrics transfers
`heat away from the body up to two times more effectively than cotton. This is critically
`important not only for sustained comfort during sleep, but also in terms of enabling the body to
`cool itself as rapidly as possible to facilitate sleep onset. In addition to trapping less heat,
`performance bedding breathes better than cotton — up to 50% better, giving performance bedding
`a strong advantage in terms of ventilation and heat and moisture transfer.
`
`6
`
`000324
`
`
`
`WO 2010/037082 (cid:9)
`
`PCT/US2009/058716
`
`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
`managing moisture (e.g., sweat) to maintain thermal comfort. In addition to wicking moisture
`away from the skin through capillary action, the performance fabric's advanced breathability
`further enables heat and moisture transfer through evaporative cooling. As a result, the user is
`kept cooler, drier and more comfortable than with cotton.
`
`The present performance bedding holds a distinct advantage over cotton in enabling,
`accommodating and maintaining optimum thermal conditions for sleep, which in turn can lead to
`faster sleep initiation and deeper, more restorative sleep.
`
`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.
`
`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.
`
`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
`singular forms "a," "an" and "the" include plural referents unless the context clearly dictates
`otherwise. For example, reference to a sheet or portion is intended also to include the
`
`7
`
`000325
`
`
`
`WO 2010/037082 (cid:9)
`
`PCT/US2009/058716
`
`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 from "about" or "approximately" one particular value
`and/or to "about" or "approximately" another particular value. When such a range is expressed,
`another embodiment includes from the one particular value and/or 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, particles, 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 from 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
`fit 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
`
`8
`
`000326
`
`
`
`WO 2010/037082 (cid:9)
`
`PCT/US2009/058716
`
`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 3/4 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 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 is shown having dimensions of 91 inches wide and 102 inches
`in length. In this embodiment, stitching 14 is shown 34 inches from an interior edge 18 of a
`main portion 16 and another stitch 14 at edge 20 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
`
`000327
`
`
`
`WO 2010/037082 (cid:9)
`
`PCT/US2009/058716
`
`Stitching used for securing the portions of the sheet together can include that shown as
`28a. 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
`perfoiniance 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 34a
`through 34d 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 portions/panels 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 17 or more cylinder
`
`10
`
`000328
`
`
`
`WO 2010/037082 (cid:9)
`
`PCT/US2009/058716
`
`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 outerwear.
`
`"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 (e.g. capillary action)
`at play. Further, the use of cotton comes at the expense of breathability and heat-transfer
`capabilities (as confirmed by laboratory testing) and stretchability.
`
`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
`
`000329
`
`
`
`WO 2010/037082 (cid:9)
`
`PCT/US2009/058716
`
`without departing from the spirit and scope of the invention and its equivalents as set forth in the
`following claims. Therefore, other modifications or embodiments 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
`
`000330
`
`
`
`WO 2010/037082 (cid:9)
`
`PCT/US2009/058716
`
`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.
`
`The method according to Claim 1, wherein forming at least two discrete performance
`2.
`fabric portions comprises knitting at least two discrete performance fabric portions.
`
`The method according to Claim 1, wherein forming at least two discrete performance
`3.
`fabric portions comprises circular knitting at least two discrete performance fabric portions.
`
`The method according to Claim 1, wherein joining at least two discrete performance
`4.
`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 portions; and
`
`stitching at least two discrete performance fabric portions together to form the finished
`
`fabric.
`
`6.
`
`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
`
`The method according to Claim 5, further comprising providing piping to the finished
`
`7.
`fabric.
`
`8.
`fabric.
`
`A method of making a