Durable Drop Area Flat Weave Fabric Bedding and Related Processes

Abstract

A woven sheet, more specifically a fitted sheet, has a woven top cover that covers the top surface of a mattress and a drop area for fitting around all four sides and corners of the mattress. The woven fabric of the top cover consists of plain weave made of natural fibers and / or natural fiber blends and / or blends of natural and chemical fibers. The woven fabric of the drop area consists of plain weave made of chemical fibers and / or chemical fiber blends. The drop area is sewn around the perimeter of the top cover. The sewn woven sheet is sustainable, economical, quick-drying, durable, and suitable for bedding use.

Description

Technical Field

[0001] Cross - reference to related applications This application claims the benefit and priority of Indian Patent Application No. 20222103921, filed on July 7, 2022, the entire content of which is incorporated herein by reference.

[0002] The present disclosure relates to a woven sheet, more specifically a fitted sheet, having a woven top cover that covers the top surface of a mattress and a drop area for fitting around all four sides and corners of the mattress.

Background Art

[0003] The textile industry is a major source of employment and revenue creation globally. In recent years, the textile industry has made several technological advancements and adopted environmentally safe operating procedures. Further, the textile industry has made further progress by improving the durability of fabrics that are globally applicable.

[0004] Conventional fitted sheets have a woven top cover that covers the top surface of a mattress and a drop area for fitting around all four sides and corners of the mattress. These conventional woven sheets are typically made from either natural fibers, natural fiber blends, chemical fibers, chemical fiber blends, or any combination thereof. However, the comfortable and sophisticated appearance in a woven sheet is far superior in sheets made of 100% natural fibers or natural fiber blends compared to sheets manufactured using chemical fibers. Thus, customers and users of sheets prefer woven sheets made of natural fibers.

[0005] There are various patented box sheets. For example, in U.S. Patent No. 7,398,570, a box mattress cover is disclosed that includes a top panel of material for fitting when covering the top surface of a mattress, and an outer peripheral skirt that hangs down from the outer periphery of the top panel for fitting in a covering relationship with the sides and ends of the mattress. The outer peripheral skirt includes a pair of stretchable side wall panels attached to the top panel, the side wall panels being sized and configured to substantially cover the entire side of the mattress, and a pair of stretchable end panels attached to the top panel, at least one of the end stretchable end panels being sized and configured to substantially cover only the upper portion of the end wall of the mattress, and at least one stretchable end panel being sized and configured to substantially cover only the lower portion of each end wall below the upper portion. The stretchable end panel is formed from a stretchable material that is stretchable at least in its longitudinal direction so as to generate at least a partial restoring force. The stretchable end panel is attached along its upper edge to the corresponding peripheral edge of one of the stretchable end panels, and at its end is attached either directly or indirectly to the corresponding edge of the side wall panel. When installed, the mattress cover fits into the edges of the side wall panels by at least a partial restoring force.

[0006] U.S. Patent Application Publication No. 20050193490 discloses a mattress pad having a central rectangular panel comprising a plurality of layers including an upper fabric layer, a lower fabric layer, and a batting layer quilted to at least one of the upper fabric layer and the lower fabric layer. This includes side panels that hang down from the central panel and comprise a single layer of woven fabric. The end panels are defined by extensions of the central panel. The side panels are joined to the end panels by seams that extend in the transverse direction relative to the rectangular central panel. To fit a woven sheet over the mattress, the drop area of the sheet is inserted under the mattress and, in some cases, over a hard surface such as a wooden or metal bed or floor. This movement to fit the woven sheet causes the drop area to experience more wear and tearing compared to the top cover. Due to wear and tearing, there is a high likelihood that the drop area will break. The durability of natural fiber sheets is also extremely low compared to chemical fiber sheets. Additionally, these sheets consume more energy to dry due to the high moisture content of natural fibers. The above patent does not address these problems.

[0007] Recent advancements in the manufacture of durable woven sheets include sheets with a high thread count. However, conventional high thread count sheets are costly because they require more raw materials and more manufacturing requirements, such as electricity, machinery, and labor. Naturally, the cost of high thread count woven sheets is also high. Additionally, conventional natural fabrics, which can be low or high thread count woven sheets, have a longer drying time. As a result, the energy consumption required for sheets made from natural fibers further increases.

[0008] Accordingly, in light of the foregoing description, there is a practical need to overcome the aforementioned drawbacks associated with conventional woven sheets. The present invention has particular advantageous applications for box bed sheets that are sustainable, economical, quick-drying, and durable. SUMMARY OF THE INVENTION

[0009] Embodiments of the present disclosure are bedding that includes a combination of two plain fabrics, one of which includes a top cover and the other includes a drop area. The bedding described herein may include a sheet, a mattress cover, or a bed cover, such as a mattress pad, which, when used under a sheet, protects the mattress and / or provides a softer surface and a sleek, refined appearance with a smooth feel to the mattress.

[0010] The top cover of the bedding includes a plain weave fabric (referred to as the first plain weave fabric). The first plain weave fabric includes a warp yarn component that includes warp yarns and a weft yarn component that includes weft yarns, and the weft yarns are woven with the warp yarns to define a woven fabric. At least one of a) the warp yarn component and b) the weft yarn component includes a plurality of spun yarns. Each spun yarn has a length and a plurality of single yarn spun yarns or multi-filament spun yarns that are twisted together.

[0011] The drop area of the bedding includes a second plain weave fabric. The second plain weave fabric includes a warp yarn component that includes warp yarns and a weft yarn component that includes weft yarns, and the weft yarns are woven with the warp yarns to define a woven fabric. At least one warp yarn component includes a plurality of spun yarns, and the weft yarn component includes a spun yarn or a filament yarn. Each spun yarn has a length and a plurality of single yarn spun yarns or multi-filament spun yarns that are twisted together. The filament yarn is made from one or more continuous filament strands where the filaments of each component extend along the entire length of the yarn. A monofilament yarn is a yarn composed of one single filament, and more than one filament is a multifilament yarn.

[0012] Another embodiment of the present disclosure is a process for manufacturing bedding. The process includes cutting and sewing the drop area and the top cover to form a flat bedding. In one example, the cutting step includes cutting the top cover and the drop area. In another example, the sewing step includes sewing the top cover and the drop area to form a flat cloth sheet.

[0013] The foregoing summary of the invention and the following detailed description of exemplary embodiments of the present application will be better understood when read in conjunction with the accompanying drawings. For the purpose of explaining the present application, exemplary embodiments of the present disclosure are shown in the drawings. However, it should be understood that the present application is not limited to the exact arrangements and instruments shown.

Brief Description of the Drawings

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DETAILED DESCRIPTION OF THE INVENTION

[0015] Embodiments of the present disclosure include a bedding 100 having a unique flat fabric structure, including fiber types and their blends, yarns, fabrics, and related articles that are highly absorbent, flexible, comfortable, durable, economical, and suitable for home textile applications. The flat fabric structure may be suitable for bedding including woven sheets, mattress covers, and bed covers, such as mattress pads used under sheets to protect the mattress and / or to provide a softer surface, and may give the mattress a smooth feel and a sophisticated appearance. Also described herein are the processes and apparatuses used to manufacture the flat fabric. As used herein, the term "fitted sheet" is used in its general sense to include, but not be limited to, sheets, bed sheets, mattress covers, or bed covers for providing a smooth and comfortable feel and a sophisticated appearance to a mattress. The present invention has particular advantageous applications for sustainable, economical, quick-drying, and durable fitted bed sheets.

[0016] As shown in FIGS. 1 to 2, an embodiment of the present disclosure includes a bedding 100. The bedding 100 includes a top cover 102 formed from a first plain weave fabric and a drop area 104 formed from a second plain weave fabric. The drop area 104 is attached to the top cover 102 by sewing or the like. The first plain weave fabric has a warp thread component including warp threads and a weft thread component including weft threads, and the weft threads are woven with the warp threads to define the plain weave fabric. As shown, at least one of a) the warp thread component and b) the weft thread component includes a plurality of spun yarns. The second plain weave fabric is different from the first plain weave fabric. The second plain weave fabric has a warp thread component including warp threads and a weft thread component including weft threads, and the weft threads are woven with the warp threads to define the plain weave fabric. In the second plain weave fabric, at least one of a) the warp thread component and b) the weft thread component includes a spun yarn or a filament yarn made from chemical fibers respectively. The different thread structures and fabric structures of the first and second plain weave fabrics will be further described below.

[0017] In FIGS. 1 to 14, different configurations of the bedding 100 are shown. Different part numbers are used to indicate different components of different embodiments, but each embodiment is a bedding including a top cover and a drop area. The same reference numbers are used for features common to all embodiments.

[0018] Referring to FIG. 2, a bottom view of the bedding 100 having four elastic bands 206 sewn to four corners in contact with the bottom end of the drop area 104 is shown.

[0019] In FIG. 3, the drop area 304 is sewn around the top cover 302 together with the elastic band 306. As shown, the elastic band 306 extends around the entire outer peripheral portion of the top cover. FIG. 4 shows an isometric view of a bedding including a top cover 402 and a drop area 404 having a box pleat effect 408 along each side of the bedding 100. FIG. 5 shows a bottom view of the bedding shown in FIG. 4, with four elastic bands 506 located at the corners of the bottom end of the drop area 404.

[0020] Figure 6 shows another version of the bedding 100 including a top cover 602 and a drop area 604 stitched around the top cover 602 together with an elastic band 606. The drop area 604 is stitched with a box pleat effect 608.

[0021] Figure 7 is another version of the bedding 100 including a top cover 702 and a drop area 704 stitched around the outer periphery with self-piping 710. Further, the bottom end of the drop area 704 is stitched together with an elastic band 706 around the entire perimeter of the bottom end of the bedding 100.

[0022] Figure 8 is another version of the bedding 100 including a top cover 802 and a drop area 804 stitched around the outer periphery of the top cover 802 with contrast piping 812. Further, an elastic band 806 is stitched around the entire perimeter of the bottom end of the drop area 804 at the bottom end.

[0023] Figure 9 is another version of the bedding 100 including a top cover 902 and a drop area 904 stitched around the outer periphery of the top cover 902 with contrast flat and cord piping 914. Further, an elastic band 906 is stitched around the entire perimeter at the bottom end of the drop area 904.

[0024] Figures 10 and 11 show yet another version of the bedding 100 including a top cover 1002 and a drop area 1004 stitched around the top cover 1002. Further, an elastic band 1006 is stitched around the entire perimeter of the bottom end of the drop area 1004 at the bottom end. T-shaped elastic bands 1016 are further stitched at the four corners of the drop area.

[0025] Figures 12 to 14 show different deformation forms for fixing the bedding 100 in place. In Figure 12, the bedding 100 includes a top cover 1202 and a drop area 1204 sewn around the top cover 1202. Further, at the bottom end of the drop area, surface fastener systems 1218, 1220 are sewn. In one example, the surface fastener is a Velcro band. In one example, a hook portion 1218 is sewn to one corner of the drop area 1204, and a loop portion 1220 is sewn to an adjacent corner.

[0026] Figure 13 shows the bedding 100 having a top cover 1302 and a drop area 1304 sewn around the top cover 1302. Further, at the bottom end of the drop area 1304, a slide fastener system 1322 is sewn. One side of the slide fastener is sewn to one corner of the drop area 1304, and the extendable other side of the slide fastener is sewn to the next adjacent corner, and the slide fastener system 1322 is completed using a runner.

[0027] Figure 14 shows the bedding 100 having a top cover 1402 and a drop area 1404 sewn around the top cover 1402. Further, at the bottom end of the drop area 1404, snap fasteners 1424 are sewn.

[0028] Each bedding shown in Figures 1 to 14 and described above is made from a first plain woven fabric for the top cover and a second plain woven fabric for the drop area. Further, each component shown in Figures 1 to 11, for example, elastic bands, pipings, pleats, T-shaped elastic bands, may be used in combination with the surface fasteners, slide fasteners, or snap fasteners shown in Figures 12 to 14. Further, each component shown in Figures 1 to 11, for example, elastic bands, pipings, pleats, T-shaped elastic bands, may be used in combination with each other as necessary.

[0029] The thread configurations described in this disclosure can have several different structures. In one embodiment, the thread configuration is a spun yarn formed from single filaments and / or multifilaments. Each spun yarn has a length and a plurality of single-filament spun yarns or multifilament spun yarns twisted together. In another embodiment, the spun yarn may be made from 100% natural fibers. In yet another embodiment, the spun yarn may be made from 100% natural fiber blends. In another embodiment, the spun yarn may be made from 100% chemical fiber staples. In yet another embodiment, the spun yarn may be made from 100% chemical fiber staple blends. In another embodiment, the spun yarn can be made from natural fibers or natural fiber blends and chemical fiber staples or chemical fiber staple blends or any combination thereof. In another embodiment, the thread configuration is a filament yarn. The filament yarn is made from one or more continuous filament strands where the filaments of each component extend over the entire length of the yarn. A monofilament yarn is a yarn composed of a single filament, and more than one filament is a multifilament yarn.

[0030] The plain cloth described in this specification can be defined by the repetition of several different weaves or patterns. Depending on the specific pattern, the repetition of the pattern may be repeated along the weft direction and the warp direction, or both the weft direction and the warp direction. However, the pattern of the woven fabric is not limited to any specific weave. For example, the woven fabric can have several exemplary weaves including, but not limited to, plain weave, twill weave, rib weave (e.g., 2×1 rib weave, 2×2 rib weave, or 3×1 rib weave), herringbone weave, Oxford weave, percale weave, satin weave (e.g., satin dobby base, satin stripe satin 5 / 1, satin 4 / 1 satin; 4 / 1 satin base stripe; 4 / 1 satin Swiss dot; 4 / 1 down jacquard; 5 / 1 satin), or bamboo weave. In one example, the woven fabric is plain weave. In another example, the woven fabric is twill weave. In another example, the woven fabric is rib weave. In another example, the woven fabric is herringbone weave. In another example, the woven fabric is Oxford weave. In another example, the woven fabric is bamboo weave. In another example, the woven fabric is any other possible weave. In another example, the woven fabric is satin weave. Further, several exemplary satin weaves are possible. For example, in one example of a satin weave, the woven fabric is 4 / 1 satin. In another example, the woven fabric is 4 / 1 satin dobby diamond weave. In another example, the woven fabric is 4 / 1 satin dobby stripe. In yet another example, the woven fabric is 4 / 1 satin jacquard weave. In another example, the woven fabric is 5 / 1 satin. In yet another example, the woven fabric may be 6 / 1 satin. In another example, the woven fabric is 7 / 1 satin. In yet another example, the woven fabric is 8 / 1 satin. In another example, the woven fabric is 9 / 1 satin. And in another example, the woven fabric is 10 / 1 satin.

[0031] As will be described in further detail below, in a single weft insertion event during weaving, a co-insertion technique can be utilized to insert multiple weft yarns along the weft insertion path. Those skilled in the art will understand that the weft insertion path varies depending on the weave pattern. By inserting a group of multiple weft yarns into the shed during a weft insertion event, an increase in the weft (or pick or lateral) density allows for an increase in the thread count. Thus, the woven fabric described herein can be constructed to have a higher weft density, and thus a higher thread count, than would be possible by other means, yet still exhibit desirable fabric quality, softness, hand feel, and drape suitable for bedding applications. The thread count of a woven fabric made in accordance with the present disclosure can generally be greater than about 100 and as high as (or greater than) about 2000. As used herein, the thread count is the total number of yarns in one square inch of fabric. In this context, the thread count is based on the total number of yarn ends. In other words, plied yarns are considered as one yarn for the purpose of determining the thread count.

[0032] As will be described in further detail below, in a single weft insertion event during weaving, a co-insertion technique can be utilized to insert multiple weft yarns along the weft insertion path. The "co-insertion" technique is a technique in which multiple picks or weft yarns are inserted into the warp shed at once during weaving. In co-insertion, two pick yarns supplied from two different yarn packages are inserted through the shed at once during weaving. Co-insertion may also include inserting three or more yarns supplied from three or more different yarn packages into the shed during weaving. In one example, the woven fabric has between one (1) and seven (7) weft yarns inserted along the weft insertion path during a single insertion event.

[0033] The warp and weft yarns are arranged to achieve a desired warp and weft yarn end density, and thus a desired thread count, for bedding applications. According to embodiments of the present disclosure, the woven fabric has a warp yarn end density between about 50 warp yarn ends per inch and about 550 warp yarn ends per inch. In one example, the warp yarn end density is between about 50 and about 150 warp yarn ends per inch. In another example, the warp yarn end density is between about 150 and about 250 warp yarn ends per inch. In another example, the warp yarn end density is between about 250 and about 350 warp yarn ends per inch. In another example, the warp yarn end density is between about 350 and about 450 warp yarn ends per inch. In another example, the warp yarn end density is between about 450 and about 550 warp yarn ends per inch. Further, the weft yarns are arranged to define a weft yarn end density between about 50 weft yarns per inch and about 1500 weft yarns per inch (or more) of the woven fabric. In one example, the weft yarn density is between about 100 and about 1500 weft yarns per inch. In one example, the weft yarn density is between about 100 and about 300 weft yarns per inch. In another example, the weft yarn density is between about 300 and about 500 weft yarns per inch. In another example, the weft yarn density is between about 500 and about 700 weft yarns per inch. In another example, the weft yarn density is between about 700 and about 900 weft yarns per inch. In another example, the weft yarn density is between about 900 and about 1100 weft yarns per inch. In another example, the weft yarn density is between about 1100 and about 1300 weft yarns per inch. In another example, the weft yarn density is between about 1300 and about 1500 weft yarns per inch. As used herein, the weft yarn density refers to the total number of distinct weft yarns along the length of the woven fabric. For example, a weft yarn density of about 50 picks per inch refers to a total of 50 weft yarns per inch of the woven fabric. If weft yarn groups are inserted during a single weft yarn insertion event and each group contains three (3) weft yarns, there are a total of about 16 groups of weft yarns per inch of the fabric and 48 picks per inch.

[0034] The yarn can have a count range for different fibers and weave structures as described herein. The count used in this paragraph refers to the count per single yarn and the count of multifilament yarns. The count can be in the range between about 8 Ne (664 denier) and about 140 Ne (37.9 denier). In one example, the yarn can have a count within the range between about 8 Ne (664 denier). In one example, the yarn can have a count within the range between about 20 Ne (266 denier). In one example, the yarn can have a count within the range between about 30 Ne (177 denier). In one example, the yarn can have a count within the range between about 40 Ne (133 denier). In another example, the yarn has a count of about 60 Ne (88.6 denier). In another example, the yarn has a count of about 70 Ne (75.9 denier). In another example, the yarn has a count of about 80 Ne (66.4 denier). In another example, the yarn has a count of about 100 Ne (53.1 denier). In another example, the yarn has a count of about 120 Ne (44.3 denier). In the case of plain woven fabric, the count of the warp yarn can range from 20 Ne (266 denier) to about 100 Ne (53.1 denier). The count of the weft yarn can range from 20 Ne (266 denier) to about 140 Ne (37.9 denier).

[0035] Plain cloth can use different yarn structures for the warp and weft yarn components. In one example, the warp yarn is a common spun yarn (cotton, or a fiber blend of either natural fiber and chemical fiber, or 100% chemical fiber), and the weft yarn includes a single yarn or multifilament spun yarn of a fiber blend of either natural fiber and chemical fiber or 100% chemical fiber. In one example, the warp yarn is a common continuous filament yarn, and the weft yarn is a single yarn or multifilament spun yarn. In another example, the weft yarn is a common spun yarn, and the warp yarn is a single yarn or multifilament spun yarn. In one example, the weft yarn is a common continuous filament yarn, and the warp yarn is a single yarn or multifilament spun yarn. In a preferred embodiment, the warp yarn is a common spun yarn, and the weft yarn includes a single yarn or multifilament spun yarn. In a preferred embodiment, the warp yarn is a common spun yarn, and the weft yarn includes a filament yarn.

[0036] The staple may be cotton fiber. Alternatively, for example, instead of cotton, it may include viscose fiber, modal fiber, kapok fiber, raime fiber, hemp fiber, ramie fiber, silk fiber, linen fiber, bamboo fiber, acrylic fiber, polyethylene terephthalate (PET) fiber, polyamide fiber, or a blend or composite fiber of fibers, carbon fiber, PLA fiber. Fiber blends may include, for example, cotton and viscose fiber blend; cotton and modal fiber blend; cotton and silk fiber blend; cotton and modal fiber blend, cotton and linen fiber blend; cotton and bamboo fiber blend; cotton and acrylic fiber blend; cotton and PET fiber blend; cotton and polyamide fiber blend; viscose and modal fiber blend; viscose and silk fiber blend; viscose and modal fiber blend, viscose and linen fiber blend; viscose and bamboo fiber blend; viscose and acrylic fiber blend; viscose and PET fiber blend; viscose and polyamide fiber blend; PET and viscose fiber blend; PET and modal fiber blend; PET and silk fiber blend; PET and modal fiber, PET and linen fiber blend; PET and bamboo fiber blend; PET and acrylic fiber blend; and PET and polyamide fiber blend, but are not limited thereto. Or there are also any other possible combinations. The PET fibers described in the present disclosure may result from PET chips. In one example, the PET chips may be those in which the PET can be dull. In another example, the PET chips may be those in which the PET can be semi-dull. In another example, the PET chips may be those in which the PET can be bright. In another example, the PET chips may be those in which the PET can be full bright.

[0037] The PET fibers described in this disclosure may have a circular cross-section (CCS). Alternatively, for example, instead of circular cross-section fibers, any non-circular cross-section (NCCS) may be used. In one example, the cross-section may be oval-shaped. In another example, the cross-section may be three-lobed. In another example, the cross-section may be four-lobed. In another example, the cross-section may be five-lobed. In another example, the cross-section may be eight-lobed. In another example, the cross-section may be multi-lobed. In another example, the cross-section may be delta-shaped. In another example, the cross-section may be cross-shaped.

[0038] In a preferred embodiment, the top area is a plain cloth made using a general spun yarn (cotton or any fiber blend natural fiber), and the drop area is a plain cloth made using any fiber blend monofilament or multifilament yarn or spun yarn of chemical fiber. To achieve a similar appearance and feel as the top area, non-circular cross-section (NCCS) chemical fibers may be used in the second plain woven fabric used in the drop area. In one example, the NCCS chemical fiber may be a PET fiber. More specifically, the use of four-lobed cross-section PET fibers may be used as the chemical fiber within the drop area. The denier of the PET filament yarn may range from 10 denier to about 300 denier. In an embodiment, the denier range of the PET filament yarn is from 10 denier to 30 denier. In yet another embodiment, the denier range of the PET filament yarn is from 30 denier to 75 denier. In yet another embodiment, the denier range of the PET filament yarn is from 75 denier to 150 denier. In yet another embodiment, the denier range of the PET filament yarn is from 150 denier to 300 denier.

[0039] As a first step, the yarn formation of natural fibers (or cotton fibers) undergoes an opening step in the carding process. In the carding process, the cotton fibers are processed by a bale plucker, an opener, a multi-mixer, a beater, and a dustex machine. After opening, the fibers are carded by a carding machine to produce a card sliver. The sliver obtained from carding is then processed through a breaker drawing step to draw out the sliver. In an example of the breaker drawing step, the number of strands combined at the feed end can be 6, and the hank delivered is maintained at about 0.10 - 0.13. In the case of mixed slivers, each component is processed separately by carding, and the individually carded slivers are then combined and mixed on a draw frame. From the breaker drawing, the sliver can continue to one of two processing steps, namely, the lapping step or the roving step.

[0040] If combing is required, the process proceeds from the breaker drawing to the lapping step. As understood, combing is used to remove short fibers during the processing of cotton. In the lapping step, a uni-lapper changes doubling into fiber laps. The laps are processed in the combing step using a comber. The combed cotton sliver is then passed through another finisher drawing step to obtain a sliver that can be used as the input for a spinning machine. In an example, the finisher draw frame has a feed hank in the range of 0.10 - 0.13 and a delivery hank at a speed of up to about 400 meters per minute in the range of 0.65 - 2.5.

[0041] Referring back to the steps, in a particular example, the sliver produced in the breaker drawing step is fed into the finisher drawing and then directly into the roving step, which will be further described below.

[0042] As a next step, the sliver is fed into a roving machine that includes an inlet capacitor, an intermediate capacitor, a main feed capacitor, a set of multiple draft rollers, and a flyer. Typically, the sliver is processed through an inlet zone, a rear draft zone, an intermediate draft zone, and a front draft zone. The capacitors are arranged along these different zones, each near or at its respective draft roller. The cotton sliver follows a normal path from the rear to the front of the roving machine, passing through at least the main feed capacitor. Roving and winding onto bobbins is common, similar to any other cotton roving system. For example, clockwise rotation of the flyer can impart a "Z" twist. Alternatively, roving can have an "S" twist by reversing the flyer's direction of rotation counterclockwise. The roving hank ranges from about 0.5 to about 2.5 hanks. In one example, the roving hank can be about 0.58. In yet another example, the roving hank can be about 1.00.

[0043] After the roving step, the yarn spinning step converts the roving into single yarns. According to the illustrated embodiment, yarn spinning is achieved on a ring spinning system using general settings to form ring spun yarns. The spinning parameters on the ring spinning system are set based on the type of fibers throughout the yarn structure. The ring spinning machine can produce single yarns with counts ranging from about 8 Ne (664 denier) to about 140 Ne (37.9 denier). Yarns used for plain woven fabrics can have counts ranging from 10 Ne to about 120 Ne (44.3 denier).

[0044] Also, yarn spinning is achieved on a rotor spinning system using general settings to form open end yarns. The spinning parameters on the rotor spinning system are set based on the type of fibers throughout the yarn structure. The rotor spinning system can produce single open end yarns.

[0045] Also, yarn spinning is achieved on a friction type open-end spinning system using general settings to form single yarns. The spinning parameters on the friction type open-end spinning system are set based on the types of fibers within the entire yarn structure. The friction type open-end spinning system can produce single yarns.

[0046] Also, yarn spinning is achieved on a self-twist spinning system using general settings to form single yarns. The spinning parameters on the self-twist spinning system are set based on the types of fibers within the entire yarn structure. The self-twist spinning system can produce single yarns.

[0047] Also, yarn spinning is achieved on an electrostatic spinning system using general settings to form single yarns. The spinning parameters on the electrostatic spinning system are set based on the types of fibers within the entire yarn structure. The electrostatic spinning system can produce single yarns.

[0048] Also, yarn spinning is achieved on a vortex spinning system using general settings to form single yarns. The spinning parameters on the vortex spinning system are set based on the types of fibers within the entire yarn structure. The vortex spinning system can produce single yarns.

[0049] Also, yarn spinning is achieved on an air-jet spinning system using general settings to form single yarns. The spinning parameters on the air-jet spinning system are set based on the types of fibers within the entire yarn structure. The air-jet spinning system can produce single yarns.

[0050] Also, yarn spinning is achieved on a twistless spinning system using general settings to form single yarns. The spinning parameters on the twistless spinning system are set based on the types of fibers within the entire yarn structure. The twistless spinning system can produce single yarns.

[0051] After thread fine spinning, the threads are further packaged into appropriate yarn packages using an auto coner. These packages are then used in various twisting steps to produce multi-filament yarns as needed. In the various twisting steps, the threads are twisted together to form multi-filament yarns. According to the illustrated embodiment, the various twisting steps use a double twister to twist two single threads together to form a double yarn. Thus, as shown, the intermediate multi-twist spun yarn is a double yarn that includes a first spun yarn to define the multi-twist yarn and a second spun yarn twisted with the first spun yarn. The intermediate multi-twist yarn has a total number of twists per inch (TPI) and can have from about 3.5 to about 14.5 TPI in the "S" direction. However, the twist direction can be in the "Z" direction. Further, the twist configuration can be either Z on S or Z on Z. The resulting twist number is from about 2 / 10s to about 2 / 120s. In an alternative embodiment, the intermediate multi-twist yarn can be a three-filament yarn. Such a three-filament intermediate yarn includes a first spun yarn, a second spun yarn, and a third spun yarn twisted into the multi-twist structure. As needed, multi-twist yarns twisted from more than three threads can be used. After the threads are multi-twisted, the multi-twist yarns are wound onto a yarn package suitable for further processing. For example, the multi-twist yarns can be wound onto the yarn package in a cross-wound manner.

[0052] As the next step, the multi-twist yarns proceed to the warping step. The warping step includes warping operations common to plain woven fabrics.

[0053] After the weaving step, the warping step follows. The weaving step converts the yarns into a woven fabric. One or more looms, such as projectile, air-jet loom, rapier loom, water-jet loom (or others), can be used during the weaving step. Each loom can utilize a common shedding mechanism such as a cam, dobby, or jacquard type shedding mechanism. During the weaving step of the woven fabric 1, the warp yarns and weft yarns can be arranged in several different weave structures and patterns, which are known to those skilled in the art and are detailed above. For example, plain woven fabrics can include plain weave, twill weave, sateen weave, herringbone weave, percale, satin, damask, and other patterns. According to an embodiment of the present disclosure, the weaving step forms the woven fabric to have a) a warp end density between about 50 warp end portions per inch to about 550 warp end portions per inch, and b) a weft end density between about 50 weft yarns per inch to about 1500 weft yarns per inch (or more) (or more). In one example, the weft yarn density is between about 100 to about 1500 weft yarns per inch. Further, the plain woven fabric can have a thread count in the range of 100TC to about 2000TC. The weaving step can include co-insertion or insertion of multiple picks during a single pick insertion event. In one example, the weaving step includes inserting between one (1) weft yarn to seven (7) weft yarns along the weft insertion path during a single insertion event. Further, in the case of a woven fabric, the weft yarns, warp yarns, or both the warp and weft yarns can include spun yarns or filament yarns. The plain woven fabric is formed to have a structure suitable for bedding applications in both the consumer, hospitality, and / or healthcare markets.

[0054] As a result of the weaving step, the "grey fabric" is further processed into a textile product. After the weaving step, the grey fabric is inspected. Following the inspection, both natural fibers and synthetic fibers can undergo either batch dyeing or continuous dyeing.

[0055] Batch dyeing involves pretreatment, i.e., desizing, scouring, bleaching, and padding, and is dyed in a common way in a padding machine. The operating temperature is maintained within the range of about 50°C to about 120°C. The operating temperature for natural fibers is maintained within the range of about 50°C to about 80°C. The operating temperature for chemical fibers is maintained within the range of about 95°C to about 120°C. After batch dyeing, the PET part can be colored by high-temperature high-pressure (HTHP) dyeing. The operating temperature for blends of natural and chemical fibers is maintained at their respective temperatures and conditions as described above in this specification. The batch dyeing step utilizes a bath ratio sufficient to facilitate the entire process and allows free movement of the fabric within the padding machine. The bath ratio can range from about 1:5 to about 1:30. For example, the bath ratio can be 1:5, 1:10, 1:12, 1:15, 1:20, 1:25, 1:22, or 1:28.

[0056] During the batch dyeing step, the fabric is usually wound into a rope shape before entering the fabric padding machine. The rotation of the rope-shaped fabric aids in uniform pretreatment and dyeing. Finishing is an optional step and can be used to apply any special chemicals as needed. After the pretreatment and dyeing operations are completed, the fabric can be rinsed, neutralized, and then removed from the dyeing container. After removing the woven fabric from the container, water is removed from the material in a dehydrator in a common way, reducing the water content from 200% to 60%. The rope is passed through a rope opener equipped with drum beaters at both the feed end and the delivery end to straighten the twist of the rope. Next, the material is passed through a hot air dryer equipped with drum beaters at both the feed end and the delivery end twice. This ensures proper raising and lowering of the pile. The first drying is carried out at about 120°C. The second drying is carried out at a higher temperature, for example 150°C, for about 4 to about 5 minutes. Next, the full-width fabric is passed through a hot air tenter and a weft straightener, and the fabric becomes straight and is returned to its proper dimensions.

[0057] As described above, after the inspection step, the green fabric can be processed in a continuous dyeing step using the continuous dyeing range and applying the processing temperature and conditions applicable to each fiber or blend. After the continuous dyeing step, the woven fabric is dried. The drying step further dries the fabric at a desired temperature using a hot air dryer. The dried fabric is spread out to its full width and then passed through a tenter step. The tenter step can help to straighten the fabric. Finishing is an optional step and can be used to apply any special chemicals if necessary.

[0058] Following the tenter step (or an optional shearing step), the cutting step cuts the woven fabric to the desired length and width according to the specific end use.

[0059] In the case of plain woven fabric, after cutting, the cut woven fabric is sewn.

[0060] Following the cutting step, the cut woven fabric can be sewn in various options to form bedding. In one option, the woven fabric of the top cover consists of a plain cloth of natural fiber and / or natural fiber blend and / or natural and chemical fiber blend. The woven fabric of the drop area consists of a plain cloth of chemical fiber and / or chemical fiber blend. The drop area is sewn around the top cover. The drop area is sewn with or without a gathering effect. Four elastic bands are sewn to all four corners in contact with the bottom end of the drop area. The gathering effect is in the range of 2:1 or 2:1.5. In this option, the sewn top cover and drop area are suitable for fitting into a mattress with a drop area of 8 inches to 20 inches.

[0061] Another option is that the woven fabric of the top cover is made of plain weave of natural fibers and / or natural fiber blends and / or natural and chemical fiber blends. The woven fabric of the drop area is made of plain weave of chemical fibers and / or chemical fiber blends. The drop area is sewn around the top cover. The drop area is sewn with or without a gathering effect. The gathering effect is within the range of 2:1 or 2:1.5. Four elastic bands are sewn to all four corners in contact with the bottom end of the drop area. In this option, the sewn top cover and drop area are suitable for fitting onto a mattress with a drop area of 8 inches to 20 inches.

[0062] Another option is that the woven fabric of the top cover is made of plain weave of natural fibers and / or natural fiber blends and / or natural and chemical fiber blends. The woven fabric of the drop area is made of plain weave of chemical fibers and / or chemical fiber blends. The drop area is sewn around the top cover together with an elastic band. The drop area is sewn with or without a gathering effect. The gathering effect is within the range of 2:1 or 2:1.5. Four elastic bands are sewn to all four corners in contact with the bottom end of the drop area. In this option, the sewn top cover and drop area are suitable for fitting onto a mattress with a drop area of 8 inches to 20 inches.

[0063] Another option is that the woven fabric of the top cover is made of plain weave of natural fibers and / or natural fiber blends and / or natural and chemical fiber blends. The woven fabric of the drop area is made of plain weave of chemical fibers and / or chemical fiber blends. The drop area is sewn around the top cover. The drop area is sewn with or without a box pleat effect. Four elastic bands are sewn to all four corners in contact with the bottom end of the drop area. In this option, the sewn top cover and drop area are suitable for fitting onto a mattress with a drop area of 8 inches to 20 inches.

[0064] In another option, the woven fabric of the top cover consists of plain weave of natural fibers and / or natural fiber blends and / or natural and chemical fiber blends. The woven fabric of the drop area consists of plain weave of chemical fibers and / or chemical fiber blends. The drop area is sewn around the top cover together with an elastic band. The drop area is sewn with or without a box pleat effect. Four elastic bands are sewn to all four corners in contact with the bottom end of the drop area. In this option, the sewn top cover and drop area are suitable for fitting onto a mattress having a drop area of 8 inches to 20 inches.

[0065] In another option, the woven fabric of the top cover consists of plain weave of natural fibers and / or natural fiber blends and / or natural and chemical fiber blends. The woven fabric of the drop area consists of plain weave of chemical fibers and / or chemical fiber blends. The drop area is sewn around the top cover together with self-piping. Further, an elastic band is sewn around the entire bottom end of the drop area. In this option, the sewn top cover and drop area are suitable for fitting onto a mattress having a drop area of 8 inches to 20 inches.

[0066] In another option, the woven fabric of the top cover consists of plain weave of natural fibers and / or natural fiber blends and / or natural and chemical fiber blends. The woven fabric of the drop area consists of plain weave of chemical fibers and / or chemical fiber blends. The drop area is sewn around the top cover together with contrast piping. Further, an elastic band is sewn to the bottom end of the drop area. In this option, the sewn top cover and drop area are suitable for fitting onto a mattress having a drop area of 8 inches to 20 inches.

[0067] Another option is that the fabric of the top cover is made of plain cloth of natural fibers and / or natural fiber blends and / or blends of natural and chemical fibers. The fabric of the drop area is made of plain cloth of chemical fibers and / or chemical fiber blends. The drop area is sewn around the top cover with either self or contrast flat and cord piping. Further, an elastic band is sewn around the entire bottom end of the drop area. In this option, the sewn top cover and drop area are suitable for fitting onto a mattress with a drop area of 8 inches to 20 inches.

[0068] Another option is that the fabric of the top cover is made of plain cloth of natural fibers and / or natural fiber blends and / or blends of natural and chemical fibers. The fabric of the drop area is made of plain cloth of chemical fibers and / or chemical fiber blends / or natural fibers / or natural fiber blends / or blends of natural and chemical fibers. The drop area is sewn around the top cover with contrast piping. Further, an elastic band is sewn to the bottom end of the drop area. In this option, the sewn top cover and drop area are suitable for fitting onto a mattress with a drop area of 8 inches to 20 inches.

[0069] Another option is that the fabric of the top cover is made of plain cloth of natural fibers and / or natural fiber blends and / or blends of natural and chemical fibers. The fabric of the drop area is made of plain cloth of chemical fibers and / or chemical fiber blends / or natural fibers / or natural fiber blends / or blends of natural and chemical fibers. The drop area is sewn around the top cover. Further, an elastic band is sewn around the entire bottom end of the drop area. At the four corners of the drop area, a T-shaped elastic band is further sewn. In this option, the sewn top cover and drop area are suitable for fitting onto a mattress with a drop area of 8 inches to 20 inches.

[0070] Another option is that the woven fabric of the top cover consists of plain weave of natural fibers and / or natural fiber blends and / or natural and chemical fiber blends. The woven fabric of the drop area consists of plain weave of chemical fibers and / or chemical fiber blends. The drop area is sewn around the top cover. Further, a velcro band is sewn to the bottom end of the drop area. A hook side is sewn to one corner of the drop area, and an extendable loop side for connecting the hook side is sewn to the next adjacent corner. In this option, the sewn top cover and drop area are suitable for fitting onto a mattress having a drop area of 8 inches to 20 inches.

[0071] Another option is that the woven fabric of the top cover consists of plain weave of natural fibers and / or natural fiber blends and / or natural and chemical fiber blends. The woven fabric of the drop area consists of plain weave of chemical fibers and / or chemical fiber blends. The drop area is sewn around the top cover. Further, a slide fastener is sewn to the bottom end of the drop area. One side of the slide fastener is sewn to one corner of the drop area, and the extendable other side of the slide fastener is sewn to the next adjacent corner, and a runner is used to complete the slide fastener system. In this option, the sewn top cover and drop area are suitable for fitting onto a mattress having a drop area of 8 inches to 20 inches.

[0072] Another option is that the woven fabric of the top cover consists of plain weave of natural fibers and / or natural fiber blends and / or blends of natural and chemical fibers. The woven fabric of the drop area consists of plain weave of chemical fibers and / or chemical fiber blends. The drop area is sewn around the top cover. Further, a snap fastener is sewn at the bottom end of the drop area. The snap can be of any type of metal or non-metal option. In this option, the sewn top cover and drop area are suitable for fitting onto a mattress having a drop area of 8 inches to 20 inches.

[0073] Although the present disclosure has been described herein using a limited number of embodiments, these specific embodiments are not intended to limit the scope of the present disclosure as otherwise described and claimed herein. The exact arrangement of the various elements and the order of the steps of the articles and methods described herein are not to be considered limiting. For example, although the steps of the method are described with reference to a continuous series of reference numerals and the progression of blocks in the figures, the method can be implemented in a specific order if necessary.

Claims

1. Bedding, A top cover having an outer periphery and formed from a first plain weave fabric, wherein the first plain weave fabric has warp components including warp threads and weft components including weft threads, the weft threads are woven together with the warp threads to define the plain weave fabric, and at least one of a) the warp components and b) the weft components includes a plurality of spun yarns, A quick-drying, durable drop area sewn to the outer periphery of the top cover, wherein the drop area is formed from a second plain weave fabric different from the first woven fabric, the second plain weave fabric having warp components including warp threads and weft components including weft threads, the weft threads being woven together with the warp threads to define the plain weave fabric, and the drop area comprises a) at least one of the warp components and b) at least one of the weft components being spun yarn or filament yarn made from synthetic fibers, Bedding that includes these features.

2. The bedding according to claim 1, wherein the chemical fibers of the spun yarn or filament yarn of the second plain weave fabric are circular cross-section fibers, non-circular cross-section fibers, or a combination of circular cross-section fibers and non-circular cross-section fibers.

3. The bedding according to claim 1, wherein the spun yarn of the first plain weave fabric is a single yarn or a multiply yarn.

4. The bedding according to claim 1, wherein the spun yarn of the first plain weave fabric comprises only natural fibers and cellulosic chemical fibers.

5. The bedding according to claim 1, wherein the spun yarn of the first plain weave fabric includes a blend of natural fibers, cellulosic chemical fibers, and other chemical fibers.

6. The bedding according to claim 1, wherein the spun yarn of the second plain weave fabric is a single-ply spun yarn or a multi-ply spun yarn.

7. The bedding according to claim 6, wherein the chemical fiber of the second plain weave fabric is a polyester fiber.

8. The bedding according to claim 1, wherein the filament yarn of the second plain weave fabric is monofilament yarn or multifilament yarn.

9. The bedding according to claim 1, wherein a) the warp thread components and b) the weft thread components of the second plain weave fabric include filament yarn but do not include spun yarn.

10. The bedding according to claim 1, wherein a) the warp thread components and b) the weft thread components of the second plain weave fabric include spun yarn but do not include filament yarn.

11. The bedding according to any one of claims 1 to 10, wherein the drop area is sewn to the top cover with at least one pleat or gather effect.

12. a. Four elastic bands attached to the bottom edge of the drop area at the corner of the bedding, or b. Four elastic T-bands attached to the corners of the bedding, The bedding according to any one of claims 1 to 10, further comprising either of the above.

13. The bedding according to any one of claims 1 to 10, wherein the entire bottom end of the drop area includes an elastic band.

14. The bedding according to any one of claims 1 to 10, wherein the drop area is sewn to the entire outer periphery of the top cover together with one of the elastic band, piping, contrast piping, cord piping, and flat piping.

15. The aforementioned drop area is as follows: a) A hook-and-loop fastener located at one corner of the drop area, b) A slide fastener located at one corner of the drop area, and c) A snap fastener located at one corner of the drop area, The bedding according to any one of claims 1 to 10, including one of the following.

16. A method for manufacturing bedding, The invention relates to weaving a first plain weave fabric, wherein the first plain weave fabric has warp components including warp threads and weft components including weft threads, the weft threads are woven together with the warp threads to define the plain weave fabric, and at least one of a) the warp components and b) the weft components comprises a plurality of spun yarns. The invention relates to weaving a second plain weave fabric, wherein the second plain weave fabric comprises warp components including warp threads and weft components including weft threads, the weft threads being woven together with the warp threads to define the plain weave fabric, and at least one of a) the warp components and b) the weft components includes spun yarn or filament yarn, each of which is made from a synthetic fiber. The first plain weave fabric is cut into the shape of a top cover having an outer periphery, The second plain weave fabric is cut into the shape of the drop area, The drop area is sewn to the outer circumference of the top cover to form the bedding, A method that includes [a certain feature].

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