Woven Contoured Bed Sheet Using Elastomeric Yarns for Mattress Fit
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Solution Overview
Problem
Contoured bed sheets made from woven fabric lack stretchability and durability, leading to issues with fitting various mattress sizes and adjustable beds, while knitted sheets are less durable and costly to process in commercial laundry settings. Existing solutions using spandex or core-spun yarns face issues with discoloration and chemical hazards.
Innovation Solution
A one-ply woven bed sheet with non-spandex, non-core spun multifilament elastomeric yarns that stretch along the warp or fill direction, providing stretchability without the need for elastic binding, maintaining the durability and laundry efficiency of woven fabrics while accommodating different mattress sizes and adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If woven fabric is used for contoured bed sheets, then durability and laundry processing efficiency are improved, but stretchability and adaptability to different mattress sizes deteriorate
Solution Approach 1:
The patent changes the physical-chemical parameters of the yarn by using elastomeric yarns with specific properties (non-spandex, non-core spun, multifilament construction) that provide stretchability while maintaining compatibility with woven fabric structure and durability requirements
Solution Approach 2:
The patent creates a composite material system by integrating elastomeric yarns into the woven fabric structure, combining the durability of woven construction with the stretchability of elastomeric materials to resolve the contradiction between strength and adaptability
2Adaptability or versatility
If knitted fabric is used for contoured bed sheets, then stretchability and adaptability to different mattress sizes are improved, but durability and ease of laundry processing deteriorate
Solution Approach 1:
The patent changes the structural parameters of the fabric by maintaining a woven construction (which provides durability) while modifying the yarn properties to include elastomeric characteristics (which provide stretchability), thus achieving adaptability without sacrificing durability or laundry processing efficiency
3Adaptability or versatility
If spandex yarns are used to add stretch to woven fabric, then stretchability is improved, but resistance to discoloration and degradation deteriorates
Solution Approach 1:
The patent extracts the elastomeric functionality from spandex yarns and implements it through alternative elastomeric yarns that are specifically selected to be resistant to chlorine and heat, thereby removing the harmful effect of spandex degradation while retaining the desired stretchability
Solution Approach 2:
The patent avoids using spandex-based yarns that have limited service life in commercial laundry settings, instead selecting elastomeric yarns with proven durability and resistance to degradation, effectively replacing a short-living material with a more durable alternative
4Adaptability or versatility
If core-spun yarns are used to add stretch to woven fabric, then stretchability is improved, but control over elastomeric content and durability deteriorate
Solution Approach 1:
The patent changes the manufacturing approach by specifying elastomeric yarns with defined properties (non-core spun, multifilament construction) that allow precise control over elastomeric content and provide consistent performance, thereby improving ease of manufacture while maintaining stretchability
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution allows for a durable, stretchable bed sheet that fits various mattress sizes and adjusts with adjustable beds, maintaining the benefits of woven fabrics while avoiding the drawbacks of knitted sheets, such as discoloration and chemical hazards, and reducing processing costs.
Implementation Method 1
a plurality of either the fill yarns, the warp yarns, or both are elastic, non-spandex, non-core spun, multifilament elastomeric yarns whereby the contoured bed sheet is stretchable at least along the elastomeric yarns
Data Source
Figure 1~3A
Figure 2
Figure 4~4A
AI summary
A bed sheet (68) defined by a one-ply woven web (10, 100, 200) of warp yarns (50, 50') and fill yarns (52, 52') having a top (70) and a side panel (72, 74, 76, 78) depending from the top panel (70). The warp yarns (50, 50') extend in a warp direction (54 or 56) through the top (70) and side panel (72, 74, 76, 78) and the fill yarns (52, 52') extend in a fill direction (54 or 56) through the top (70) and the side panel (72, 74, 76, 78). A plurality of fill yarns(52, 52'), warp yarns (50, 50'), or both (50, 50', 52, 52') are a non-spandex, non-core spun elastomeric yam whereby the bed sheet (68) is stretchable at least along the elastomeric yarns as a contoured bed sheet (68). In one example, the non-spandex, non-corespun elastomeric yarns are composed of elasterell-p.