(12) United States Patent
`Smith, III et al.
`
`US006277770B1
`(10) Patent No.:
`US 6,277,770 B1
`(45) Date of Patent:
`Aug. 21, 2001
`
`(54) DURABLE, COMFORTABLE, AIR-
`PERMEABLE ALLERGEN-BARRIER
`FABRICS
`
`.
`-
`-
`_
`(75) Inventors. John Martln Smlth, III, Greensboro,
`Charles Woody Duckett, Kernersvllle,
`both of NC (Us)
`_
`_
`_
`_
`(73) Asslgnee: Preclslon Fabrlcs Group, Inc.,
`Greensboro, NC (US)
`
`( * ) Notice:
`
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 0 days.
`
`(21) Appl. No.: 09/667,614
`(22) Filed:
`Sep. 22, 2000
`
`Related US. Application Data
`
`(63) Continuation-in-part of application No. 09/165,287, ?led on
`Oct. 2, 1998.
`(60) Provisional application No. 60/061,431, ?led on Oct. 8,
`1997.
`
`Int. (:1.7 ................................................... ..
`(52) US. Cl. ........................ .. 442/ 190; 442/191; 442/ 197;
`442/123; 428/3155; 428/3157
`(58) Field of Search ................................... .. 442/190, 191,
`442/ 197, 123; 428/3044, 315.5, 315.7
`
`(56)
`
`References Cited
`
`U'S' PATENT DOCUMENTS
`11/1983 Marshall 61 a1, _
`4,416,787
`5/1985 PlotZker.
`4,515,761
`4,582,747 * 4/1986 Hirakawa ........................ .. 428/3179
`4,822,667
`4/1989 Goad ct a1~ -
`4,967,456
`11/1990 Sternlieb et al. .
`4,995,151
`2/1991 Siegel et al. .
`5,024,851
`6/1991 Goad et al. .
`5,050,256
`9/1991 Woodcock .
`5,271,947
`12/1993 Miller et al. .
`
`5,321,861
`5,368,920
`5,409,761
`5,424,117
`5,626,950
`576327072
`5 856 245
`5:939:340
`5,966,759
`670177601
`6,040,251
`
`6/1994 Dancey et al. .
`11/1994 Schortmann.
`4/1995 Langely.
`6/1995 Helman et al. .
`5/1997 Shimano et al. .
`5/1997 Simon et a1‘ '
`1/1999 Caldwell et a1
`8/1999 Gabbay .
`10/1999 Sanders et al. .
`1/2000 Amsel _
`3/2000 Caldwell .
`
`FOREIGN PATENT DOCUMENTS
`667196
`9/1998 (CH) '
`600459
`6/1994 (EP) _
`0 908 122
`4/1999 (EP) .
`695703
`8/1953 (GB) .
`96/21379
`7/1996 (WO) .
`
`* cited by examiner
`
`Primary Examiner—EliZabeth M. Cole
`(74) A1707‘ "6y; Agent, 07' Firm—FiI1n9gan, Henderson,
`FaraboW, Garrett & Dunner, L.L.P.
`
`(57)
`
`ABSTRACT
`
`An a11ergen_barrier fabric includes a tightly-Constructed
`fabric substrate, Woven from O to 45% continuous synthetic
`?lament yarns and 55 to 100% natural or synthetic spun
`yarns. The fabric substrate is ?nished to produce a fabric
`With a mean pore siZe of 4 to 10 microns, an air permeability
`of 0.5—25 cfm, a mean fabric ?exibility of 0.5 to 6.5 grams
`(bending resistance), and a moisture vapor permeability in
`excess of 800 g/m2/24 hours. This fabric provides a barrier
`to mite-induced allergen particles. Various additional ?n
`ishes can be included on the fabric. For example, an anti
`microbial ?nish may be provided on the fabric to extend
`fabric Wearlife
`providing protection against mold and
`mildeW. As another alternative, a ?uorochemical ?nish can
`be provided to extend fabric Wearlife by providing protec
`tion against ?uid stains.
`
`32 Claims, No Drawings
`
`IPR2017-00524
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`

`
`US 6,277,770 B1
`
`1
`DURABLE, COMFORTABLE, AIR
`PERMEABLE ALLERGEN-BARRIER
`FABRICS
`
`This is a continuation-in-part of application Ser. No.
`09/165,287, ?led Oct. 2, 1998, pending and causing bene?t
`of provisional application 60/061 431 ?led Oct. 8, 1999.
`
`FIELD OF THE INVENTION
`This invention relates to allergen-barrier fabrics that are
`durable, air-permeable, and comfortable. The fabrics
`according to this invention have improved softness and feel
`While still providing an allergen barrier that substantially
`impedes and/or stops passage of dust, dust mites, and other
`allergens through the fabric.
`BACKGROUND OF THE INVENTION
`Amaj or source of indoor allergy-causing proteins are dust
`mites. Dust mites, 100 to 300 microns in siZe, cannot be seen
`With the naked eye. Dust mite excrement, Which is a key
`component that causes allergic reactions, is even smaller,
`ranging in siZe doWn to 10 microns. Thus, in order to be an
`effective barrier to dust, dust mites, and their allergy-causing
`particles, a fabric or material must limit the transmission of
`10 micron particles through its planar surface. These facts
`are discussed, for example, in Platts-Mills TAE, et al., “Dust
`Mite Allergens and Asthma: Report of a Second Interna
`tional Workshop,” J. Allergy Clin. Immunology, 1992, Vol.
`89, pp. 1046—1060 (“Several studies have demonstrated that
`the bulk of airborne group I mite allergen is associated With
`the relatively ‘large’ fecal particle, 10 to 40 Vm in
`diameter”); AllerGuard Pte Ltd. Website, 1996 (“The house
`dust mite cannot be seen With the naked eye, as it only
`measures 0.1 to 0.5 mm” [Which corresponds to 100 to 500
`microns]); and US. Pat. No. 5,050,256 to Woodcock, et al.,
`(e. g., column 1, lines 44—46—“Ideally, if the mite barrier has
`pores, it should have a pore siZe generally less than 10
`microns. It is apparent that anything smaller causes no
`allergic reaction.”). The Platts-Mills and Woodcock docu
`ments each are entirely incorporated herein by reference.
`The major concentration of dust mites in the home is
`found in the bedroom. For example, an average mattress can
`support a colony of 2 million dust mites. PilloWs also are an
`excellent habitat for dust mites. Six-year old pilloWs typi
`cally have 25% of their Weight made up of dust, dust mites,
`and allergen. Sofa cushions, chair cushions, carpets, and
`other foam or ?ber ?lled articles also provide a suitable
`habitat for dust mites. In effect, every home contains many
`areas Where dust mites can thrive.
`Additionally, the presence of allergens from dust mites is
`a problem that increases as pilloWs, mattresses, and the like
`become older. During its lifetime, a typical dust mite pro
`duces up to 200 times its net body Weight in excrement. This
`excrement contains the allergen that triggers asthma attacks
`and allergic reactions, including congestion, red eyes,
`sneeZing, and headaches. The problem is exacerbated by the
`fact that it is dif?cult to remove dust mites from the materials
`in Which they thrine. PilloWs are rarely laundered, While
`most mattresses are never Washed.
`Commercially-available allergy-relief bedding products
`offer a Wide array of claims regarding their ef?cacy as
`allergen barriers. These products are assumed to function as
`allergen barriers because they form an impervious ?lm (as
`With the laminates) or because they are “tightly Woven” (as
`With 300-count cotton sheeting) of because they have a pore
`siZe that is too small to permit allergen penetration (as With
`nonWovens).
`
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`Each of the above-noted products, hoWever, has its oWn
`associated disadvantages. Laminated or coated materials
`typically are uncomfortable (due to little or no moisture
`vapor permeability), stiff, not soft to the touch, and noisy
`(i.e., make relatively loud, rustling noises When a person
`moves on the sheet or pilloW). Additionally, While vinyl,
`polyurethane, and microporous coated fabrics are consid
`ered excellent barriers to allergens, they require venting
`When used as pilloW or mattress tickings since air How is not
`possible through these materials. US. Pat. No. 5,050,256
`describes such a product. PilloWs or mattresses covered With
`these materials cannot de?ate and re-in?ate When
`compressed, unless they are vented. The need to vent these
`fabrics, hoWever, begs the question of Whether they can be
`considered effective allergen barriers (as allergens can also
`enter and escape through the vents). Coated and laminated
`fabrics also tend to have a limited Wearlife due to coating
`delaminator.
`Uncoated cotton sheetings, although promoted as such,
`are not true barriers to) allergens due to their inherently large
`pore siZes. Allergy specialists routinely urge patients to
`launder their bedding products on a Weekly basis. Such
`practices, hoWever, only serve to further enlarge the pore
`siZe of cotton sheetings as ?ber is lost With extended
`laundering.
`Spunbond/meltbloWn/spunbond (SMS) polyole?n non
`Wovens used in mattress and pilloW covers do provide a
`degree of barrier protection to allergens. SMS nonWovens
`also exhibit excellent air porosity. Their Wearlife, hoWever,
`is very short, particularly With hot laundering temperatures
`normally used by allergy sufferers. SMS nonWoven fabrics
`also have a signi?cantly stiffer and harsher hand as com
`pared With standard pilloW tickings.
`Other barrier products are knoWn from the literature and
`are available on the market. For example, US. Pat. No.
`4,822,667 issued to Goad et al. describes a reusable,
`launderable, steriliZable medical barrier fabric Woven from
`100% polyester ?ber constructed of polyester yarn. This
`fabric is said to be blood and aqueous ?uid transmission
`resistant, abrasion resistant, ?ame resistant, lint free,
`drapable, and suf?ciently porous to eliminate heat build-up.
`The described material is used in medical garments, Wraps,
`and steriliZable articles. This patent does not describe the use
`of the fabric as an allergen barrier. The Goad patent is
`entirely incorporated herein by reference.
`US. Pat. No. 5,050,256 issued to Woodcock describes an
`allergen proof bedding system With a cover permeable to
`Water vapor. As noted above, this patent is entirely incor
`porated herein by reference. The cover material described in
`this patent is made of Baxenden Witco?ex 971/973 type
`polyurethane-coated Woven polyester or nylon fabric. This
`fabric is not air permeable; hoWever, it does have a moisture
`vapor transmission (“MVT”) rate of 2,500 to 7,000 g of
`Water/mZ/day. Typically, the coated side of the fabric is on
`the inside of the seWn cover, and the seams are sealed. This
`product, hoWever, has the disadvantages of coated or lami
`nated materials described above.
`US. Pat. No. 5,368,920 issued to Schortmann
`(International Paper Co.) describes a nonporous, breathable
`barrier fabric and related methods of manufacture. The
`fabric is a breathable barrier fabric created by ?lling void
`spaces in a fabric substrate With ?lm-forming clay-latex
`material having a density range of 1,000 to 2,000 gm/l, to
`provide a barrier fabric permeable to Water vapor and
`impermeable to liquids and air. The MVT rate ranges from
`300 to 3,000 g/mZ/day. Applications include industrial,
`
`IPR2017-00524
`Fredman EX1026 Page 2
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`

`
`US 6,277,770 B1
`
`3
`hospital, and other protective coverings. Again, this product
`has the disadvantages associated With coated and laminated
`fabrics, as described above.
`Dancey, in US. Pat. No. 5,321,861, describes a protective
`cover for upholstered or padded articles, such as bedding,
`made from a microporous ultra?lter material having a pore
`siZe of less than 0.0005 mm. This material suppresses
`passage of fecal particles produced by house dust mites. To
`prevent particles from bypassing the ultra?lter material, the
`seams of the cover are Welded, and its opening is sealed by
`a resealable fastener, such as a Zip-fastener, covered With an
`adhesive tape.
`SUMMARY OF THE INVENTION
`It is an object of this invention to overcome the various
`disadvantages of the knoWn allergen and barrier fabric
`materials and to provide a fabric that is soft and comfortable,
`but still provides an effective barrier against transmission of
`dust, dust mites, their excrement, and other allergens.
`According to this invention, an allergen-barrier fabric
`includes a tightly-constructed fabric substrate, Woven from
`continuous natural and/or synthetic ?lament and/or spun
`yarns. The fabric substrate is ?nished so as to provide a
`fabric With a mean pore siZe of 4 to 10 microns, an air
`permeability of 0.5—25 cubic feet per minute per square foot
`of fabric at 0.5 inches of Water (“cfm,” measured by Federal
`Test Method Standard (FTM) 5450, also knoWn as ASTM
`D-737), a mean fabric ?exibility cf 0.5 to 6.5 grams
`(bending resistance), and a moisture vapor permeability in
`excess of 800 g/m2/24 hours. These speci?cations relate to
`the ?nished fabric, prior to regular use and laundering. With
`these speci?cations, the resultant fabric is soft and comfort
`able While still providing a barrier to mite-induced allergen
`particles.
`In a preferred embodiment of the invention, the allergen
`barrier fabric has a maximum initial pore siZe of 10 microns.
`Various fabric ?nishes can be included on the allergen
`barrier fabric of the invention. For example, the allergen
`barrier fabric can include an antimicrobial ?nish to extend
`fabric Wearlife by providing protection against mold and
`mildeW. As another example, the allergen-barrier fabric of
`the invention also can include a ?uorochemical ?nish to
`extend fabric Wearlife by providing protection against ?uid
`stains. These additional ?nishes can be used individually, in
`combination, or together With other possible ?nishes.
`This invention further relates to a method for providing an
`allergen-barrier for a pilloW or mattress by covering the
`pilloW or mattress With a tightly-constructed, non-coated,
`non-laminated fabric. The fabric, as noted above, is Woven
`from continuous natural and/or synthetic ?lament and/or
`yarns and ?nished to a fabric With a mean pore siZe of 4 to
`10 microns, an air permeability of 0.5—25 cfm, a mean fabric
`?exibility of 0.5 to 6.5 grams (bending resistance), and a
`moisture vapor permeability in excess of 800 g/m2/24 hours.
`This fabric provides a barrier to mite-induced allergen
`particles.
`In this invention, the allergen-barrier cover material can
`take on any suitable form. For example, it can be a pilloW
`ticking, a pilloW cover, a mattress ticking, a mattress cover,
`a mattress pad, a duet cover, or a bedspread. Furthermore,
`While it is preferred that the allergen-barrier fabric according
`to the invention cover all surfaces of the pilloW or mattresses
`so as to completely encase the pilloW or mattress, this is not
`a requirement in all embodiments. For example, typical
`mattress pads do not completely encase a mattress.
`
`DETAILED DESCRIPTION OF THE
`INVENTION
`This invention relates to an allergen-barrier fabric that
`possesses a unique combination of properties to provide an
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`allergen-barrier material that is superior to other commer
`cially available products. The fabric according to the inven
`tion has a unique combination of air porosity (to alloW
`venting through the fabric’s planar surface), moisture vapor
`transport (to enhance a user’s comfort), fabric ?exibility
`(also a comfort-enhancing property), extremely small pore
`siZe (to ?lter out allergens), and durability to laundering (as
`required of allergy-relief products) to provide that superior
`product. This combination of properties is provided by
`Weaving ?ne-denier synthetic ?lament yarns into a tight
`plain-Weave construction With post ?nishing processes that
`maximiZe ?ber coverage and ?ltration efficiency. In effect,
`the fabrics according to the invention provide the barrier
`performance of coated or laminated fabrics, While exhibiting
`the ?exibility, air porosity, and moisture-vapor porosity
`needed to enhance comfort and “re?uffability” of ?ber-?lled
`products, and While also offering a durability not possible
`With nonWoven or coated/laminated fabrics.
`The fabric material according to the invention can be used
`for any suitable purpose, but it is preferably used as a fabric
`for covering items that typically are susceptible to dust mite
`infestation. As noted above, pilloWs and mattresses provide
`a very favorable environment for sustaining dust mite colo
`nies. Therefore, advantageously, the fabric according to the
`invention can be used for pilloW tickings, pilloW covers,
`mattress pads, mattress tickings, mattress covers, duet
`covers, and/or. bedspreads. When used in such articles, the
`fabric provides a barrier to prevent dust mites from entering,
`a pilloW or mattress. Additionally, the fabric, When used in
`such articles, can prevent dust mites and allergens already
`existing in mattresses and pilloWNS from exiting the mat
`tress or pilloW e.g., When the article is compressed during
`use.
`As used in this patent application, the folloWing de?ni
`tions apply:
`A“pilloW ticking” means a pilloW’s non-removable fabric
`covering that encases the ?ber?ll or other padding.
`A“pilloW cover” means a pilloW’s removable fabric cover
`that also can function as a decorative, Washable encasement
`(e.g., a pilloW case). For allergy sufferers, a pilloW cover also
`can function as an allergen barrier. PilloW-cover closures are
`usually either Zippers or overlapping ?aps.
`A “mattress pad” is a quilted removable covering for a
`mattress. For allergy sufferers, the innermost or the outer
`most fabric in the pad can function as an allergen barrier.
`A “mattress ticking” means a mattress’s non-removable
`fabric covering that encases the ?ber?ll or other padding and
`springs.
`A“mattress cover” is a mattress’s removable fabric cover
`that also can function as a decorative, Washable encasement.
`Institutional mattress covers also must provide a barrier to
`?uids. For allergy sufferers, such a cover also can function
`as an allergen barrier. Mattress-cover closures typically are
`either Zippers or overlapping ?aps.
`Given the above background information, the invention
`Will noW be described in more detail. This invention embod
`ies a textile system that can advantageously be used as an
`integral component in pilloW covers, pilloW cases, pilloW
`tickings, mattress cases, mattress pads, mattress tickings,
`mattress covers, duet covers, and bedspreads for the purpose
`of creating a barrier to mite-induced allergen particles. The
`invention is not limited, hoWever, to these enumerated
`products. For example, the fabric according to the invention
`could be used in many other products, such as sheets,
`sleeping bags, doWn-?lled bedding, upholstered furniture,
`stuffed toys, and similar ?ber-?lled or padded items.
`
`IPR2017-00524
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`US 6,277,770 B1
`
`5
`The textile system according to the invention is comprised
`of natural and/or synthetic spun and/or ?lament yarns of
`polyester and/or nylon and/or cotton, closely Woven, and
`subsequently scoured, heat-treated, or otherWise ?nished to
`further constrict the fabric’s pore siZe. The textile fabric’s
`construction and chemical treatments are controlled to
`impart a unique combination of:
`(1) air permeability (to provide compressibility necessary
`When used in covers for ?ber-?lled bedding products);
`(2) moisture vapor permeability (to enhance sleeping
`comfort);
`(3) fabric ?exibility (also to enhance comfort);
`(4) laundering durability (to provide relatively long term
`allergen-barrier protection after several Wash cycles as
`typically required for allergy-relief textile articles); and
`(5) ?ltration ef?ciency (the paramount feature necessary
`to function as a barrier to allergens).
`The fabric according to this invention provides an excellent
`combination of these ?ve textile properties to produce a
`barrier fabric that is superior to other commercially
`available materials.
`Preferred embodiments of this invention include a fabric
`substrate made from 55—65% spun polyester and 35—45%
`?lament polyester, 55—65% spun cotton and 35—45% ?la
`ment polyester, and 100% spun cotton all by Weight, densely
`Woven in a plain Weave, With Warp and ?lling yarns totaling
`215 yarns per square inch. The preferred fabric ?nishing
`process includes scouring, heat setting, Width/length fabric
`shrinkage, and mechanical manipulation to further compact
`the yarn-to-yarn spacing. The resulting fabric product has a
`mean pore siZe of 4 to 10 microns, an air permeability of
`0.5—25 cfm (advantageously, 0.5 to 15 cfm), a mean fabric
`?exibility of 0.5 to 6.5 grams (bending resistance), and a
`moisture vapor permeability in excess of 800 g/m2/24 hours
`(advantageously 1100 to 2400 g/m2/24 hours or 1200 to
`2400 g/m2/24 hours). Mechanical manipulation can involve
`calendaring, Wherein yarns are ?attened via heat and pres
`sure to further close fabric pores; dimensional shrinkage,
`Wherein fabrics are bulked and agitated in conventional
`pressure jet equipment in such a Way as to cause Width
`and/or length shrinkage of the fabric to its minimum yarn
`spacing, or high-speed impingement and agitation via Water
`or dye liquor, Wherein ?bers are ?attened and dispersed in a
`highly uniform manner. No further coatings or ?lm lamina
`tions are required.
`As mentioned above, during production of the fabric
`according to the invention, high pressure Water or dye liquor
`can be sprayed onto the surface of the fabric. This process
`tends to maft out the fabric ?bers, thereby reducing the
`spaces betWeen ?bers and the fabric pore siZe and also
`improving the fabric softness and hand. This high pressure
`liquid impingement process also can be used to texturiZe or
`pattern the fabric, if desired. Suitable devices and systems
`for performing this high pressure liquid impingement are
`described, for example, in Us. Pat. Nos. 4,967,456; 4,995,
`151; and 5,632,072, each of Which is entirely incorporated
`herein by reference.
`Chemical enhancements to the preferred embodiment of
`the fabric according to the invention include the application
`of a permanent antimicrobial ?nish and a ?exible ?uoro
`chemical ?nish. In this context, “permanent” denotes ef?
`cacy of the respective ?nishes for the lifetime of the product.
`Any suitable antimicrobial or ?uorochemical ?nish can be
`used Without departing from this invention, and such ?n
`ishes are knoWn in the art (see, for example, U.S. Pat. No.
`4,822,667, supra.). As an example of a suitable antimicrobial
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`?nish, a very durable compound of 3-(trimethoxysilyl)
`propyidimethyloctadecyl ammonium chloride (DoW Com
`ing 5700) can be applied. This ?nish protects the fabric
`against bacteria and fungi, and inhibits the groWth of odor
`causing bacteria. It has been shoWn to be effective against
`bacteria (Streptococcus faecalis, K. pneumoniae), fungus
`(Aspergillus niger), yeast (Saccharomyces cerevisiae),
`Wound isolates (Citrobacter diversus, Staphylococcus
`aureus, Proteus mirabilis), and urine isolates (Pseudomonas
`aeruginosa, E. coli. The ?uorochemical ?nish can be a
`permanent micro-thin ?exible ?uorochemical ?lm that
`imparts ?uid repellency (see, for example, those described in
`US. Pat. No. 4,822,667, supra.). Unlike fabrics used in
`medical barrier applications, hoWever, the allergy barrier
`fabric according to the present invention is generally not
`concerned With ?uid repellency properties, as exempli?ed
`by a substantially negligible Suter rating. ASuter rating is an
`indication of a fabric’s resistance to Water penetration, as
`measured by a hydrostatic pressure test, speci?cally, the
`hydrostatic head required for three drops of Water to pen
`etrate a fabric. The loWer the Suter rating, the loWer the
`fabric’s resistance to Water penetration, i.e., the loWer the
`hydrostatic head required for three drops of Water to pen
`etrate a fabric. In the case of the claimed fabric, the Suter
`rating is beloW 20.
`The use of polyester and/or nylon and/or cotton of con
`tinuous ?lament and/or spun yarns in the fabric according to
`the invention creates a high-strength, ?exible substrate that
`is extremely durable to home and commercial laundering.
`Subsequent ?uorochemical and antimicrobial ?nishes, as
`described above, further protect the fabric against degrada
`tion due to ?uid stains, molds, and mildeW. Because the
`fabrics are tightly Woven Where yarn-to-yarn abrasion is
`restricted, there is little chance for ?ber breakage and linting.
`Therefore, fabric pore siZes remain sufficiently and consis
`tently small throughout extended laundering. This is impor
`tant because if excessive ?ber is lost during actual use or
`through extended launderings, progressively larger pore
`siZes are created and the allergen-barrier properties of the
`fabric product Would be signi?cantly deteriorated.
`Fiber-?lled products using the fabrics according to the
`invention as a covering material can be compressed and then
`recover Without the loss of allergen-barrier properties. Air
`vents are not required as an integral component of the
`fabricated product, thus reducing labor and material costs
`associated With its manufacture. The lack of air vents also
`eliminates potential entry/exit ports for dust mites and
`associated allergens.
`The ?exibility of the fabrics according to the invention
`has a very positive effect upon the drape, noise, handle, and
`comfort of the ultimate end-item. The inventive fabrics have
`a mean fabric ?exibility of 0.5 to 6.5 grains (bending
`resistance). The mean ?exibility is the mean of the bending
`resistance of the fabric in the machine direction (MD) and
`the cross machine direction (XD), measured by INDA Test
`No. IST-90.3 on a Handle-O-Meter Model 211-5. Because
`the fabrics according to the invention do not involve coat
`ings or laminations, their ?exibility and ease of movement
`is excellent.
`The fabrics according to the invention also have a mois
`ture vapor permeability or transmission rate in excess of 800
`g/m2/24 hours. In certain embodiments of the invention, the
`moisture vapor permeability is in the range of 1100 to 2400
`g/m2/24 hours, and advantageously betWeen 1200 and 2400
`g/m2/24 hours. By maintaining a moisture vapor permeabil
`ity of at least 800 g/m2/24 hours, comfort levels for the user
`are enhanced because the passage of evaporating perspira
`
`IPR2017-00524
`Fredman EX1026 Page 4
`
`

`
`US 6,277,770 B1
`
`7
`tion through the material is not impaired. This feature is a
`decided advantage over vinyl-coated products.
`Furthermore, given that the fabrics according to the
`invention are not coated or laminated, coating loss or
`delamination during use or laundering (Which leads to
`barrier performance degradation) is not possible. This is
`another advantage of the invention over coated or laminated
`products. The useful life of bedding articles fabricated from
`the fabrics according to the invention is thereby maximized.
`Finally, by maintaining a mean pore size of 4 to 10
`microns, the fabrics according to the invention are very
`effective barriers to dust mites and their allergy-causing
`excrement. In another embodiment of this invention, the
`fabric has a maximum pore size of 10 microns. This small
`maximum pore size provides long term protection against
`dust, dust mite, and allergen transmission.
`Speci?c examples of fabric products according to the
`invention folloWs. As With the more general description
`above, these examples should be construed as illustrating the
`invention and not as limiting the same.
`
`EXAMPLES
`
`This invention, as described above, includes a unique and
`unequaled combination of durability, ?exibility, air porosity,
`moisture vapor transport, and allergen-barrier performance
`as compared With existing bedding cover fabrics.
`Example 1
`A suitable fabric according to the invention Was manu
`factured from 70-denier, 34-?lament texturized polyester
`yarns, Woven in a plain-Weave construction. After Weaving,
`the fabric construction had 129 Warp ends per inch and 86
`?lling yarns per inch, With a fabric Weight of 2.28 ounces per
`yard. Subsequent processes included scouring, calendaring,
`and treating With durable antimicrobial and ?uorochemical
`?nishes. After processing, the fabric construction Was 144
`Warp ends per inch andi 89 ?lling yarns per inch, With a
`fabric Weight of 2.56 ounces per yard.
`Comfort and barrier properties for this fabric are given in
`the Table beloW:
`
`TABLE I
`
`Original
`
`After Five Launderings
`
`Pore Size
`
`Minimum
`Maximum
`Mean
`Moisture Vapor
`Transmission Rate
`Flexibility *
`Air Permeability
`
`2.060 M
`9.935 M
`4.372 M
`1,207 g/m2/24 hours
`
`2.731 M
`12.85 M
`5.156 M
`1,265 g/m2/24 hours
`
`6.1 grams
`0.622 cubic feet/minute
`
`3.2 grams
`1.130 cubic feet/minute
`
`* Measured as the mean bending resistance (grams of resistance to
`bending) of the fabric in the machine direction (MD) and the cross
`machine direction (XD) using INDA Test No. IST—90.3, Handle-O-Meter
`Model 211-5.
`
`Example 2
`A suitable fabric according to the invention Was manu
`factured from 40/1 Riing Spun Combed Cotton, Woven in a
`plain Weave construction. After Weaving, the fabric con
`struction had 112 Warp ends per inch and 124 ?lling yarns
`per inch, With a fabric Weight of 4.40 ounces per square yard.
`Subsequent processes include scouring, relax drying, and
`calendaring. After processing, the fabric construction Was
`120 Warp Einds per inch and 120 ?lling yarns per inch, With
`a fabric Weight of 4.25 ounces per square yard.
`
`8
`Comfort and barrier properties for this fabric are given in
`the Table beloW.
`
`TABLE 2
`
`Original
`
`After Five Launderings
`
`Pore Size
`
`Minimum
`Maximum
`Mean
`Moisture Vapor
`Transmission Rate
`Flexibility *
`Air Permeability
`
`4.170 M
`15.855 ,u
`4.558 M
`806 g/m2/24 hours
`
`3.809 M
`16.202 ,u
`5.014 M
`965 g/m2/24 hours
`
`9.9 grams
`3.50 cubic feet/minute
`
`4.1 grams
`6.82 cubic feet/minute
`
`* Measured as the mean bending resistance (grams of resistance to
`bending) of the fabric in the machine direction (MD) and the cross
`machine direction (XD) using INDA Test No. IST—90.3, Handle-O-Meter
`Model 211-5.
`
`Example 3
`
`A suitable fabric according to the invention Was manu
`factured from 70 denier, 34 ?lament texturized polyester
`yarn in the Warp direction, and 26/1 Air Jet Spun Polyester
`in the ?lling direction, Woven in a plain Weave construction.
`After Weaving, the fabric construction had 144 Warp ends
`per inch and 78 ?lling yarns per inch, With a fabric Weight
`of 3.73 ounces per square yard. Subsequent processes
`include scouring, and tenter frame ?nishing. After
`processing, the fabric construction Was 164 Warp ends per
`inch and 88 ?lling yarns per inch, With a fabric Weight of
`4.45 ounces per square yard.
`Comfort and barrier properties for this fabric are given in
`the Table beloW.
`
`10
`
`15
`
`20
`
`25
`
`30
`
`35
`
`TABLE 3
`
`Original
`
`After Five Launderings
`
`Pore Size
`
`40
`
`Minimum
`Maximum
`Mean
`Moisture Vapor
`Transmission Rate
`Flexibility *
`Air Permeability
`
`45
`
`8.399 M
`19.584 ,u
`8.934 M
`950 g/m2/24 hours
`
`8.046 M
`19.022 ,u
`8.990 M
`1080 g/m2/24 hours
`
`5.0 grams
`7.8 cubic feet/minute
`
`2.8 grams
`7.6 cubic feet/minute
`
`* Measured as the mean bending resistance (grams of resistance to
`bending) of the fabric in the machine direction (MD) and the cross
`machine direction (XD) using INDA Test No. IST—90.3, Handle-O-Meter
`Model 211-5.
`
`50
`
`Example 4
`
`55
`
`60
`
`65
`
`A suitable fabric according to the invention Was manu
`factured from 70 denier, 34 ?lament texturized polyester
`yarn in the Warp direction, and 28/1 open end combed cotton
`spun yarn in the ?lling direction, Woven in a plain Weave
`construction. After Weaving, the fabric construction had 144
`Warp ends per inch and 78 ?lling yarns per inch, With a
`fabric Weight of 3.58 ounces per square yard. Subsequent
`processes include scouring, and tenter frame ?nishing. After
`processing, the fabric construction Was 164 Warp ends per
`inch and 88 ?ling yarns per inch, With a fabric Weight of 3.80
`ounces per square yard.
`Comfort and barrier properties for this fabric are given in
`the Table beloW.
`
`IPR2017-00524
`Fredman EX1026 Page 5
`
`

`
`US 6,277,770 B1
`
`9
`
`TABLE 4
`
`Original
`
`After Five Launderings
`
`Pore Size
`
`Minimum
`Maximum
`Mean
`Moisture Vapor
`Transmission Rate
`Flexibility *
`Air Permeability
`
`6.088 M
`18.156 ,u
`8.992 M
`961 g/m2/24 hours
`
`6.002 M
`18.640 ,u
`9.108 M
`992 g/m2/24 hours
`
`6.8 grams
`14.5 cubic feet/minute
`
`4.4 grams
`5.8 cubic feet/minute
`
`* Measured as the mean bending resistance (grams of resistance to
`bending) of the fabric in the machine direction (MD) and the cross
`machine direction (XD) using INDA Test No. IST—90.3, Handle-O-Meter
`Model 211-5.
`
`In this application, Applicant has described certain theo
`ries and/or mechanisms in an effort to explain hoW and Why
`this invention Works in the manner in Which it Works. These
`theories and mechanisms are set forth for informational
`purposes only. Applicant is not to be bound by any particular
`chemical, physical, or mechanical theory of operation.
`While the invention has been described in terms of
`various preferred embodiments using speci?c examples,
`those skilled in the art Will recognize that various changes
`and modi?cations can be made Without departing from the
`spirit and scope of the invention, as de?ned in the appended
`claims.
`We claim:
`1.