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`IPR of U.S. Pat. No. 8,566,982
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`
`* cited by examiner
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`1
`FABRIC SYSTEM
`
`CROSS REFERENCE TO RELATED
`APPLICATION
`
`This application claims benefit under 35 USC §119(e) of
`U.S. Provisional Patent Application Ser. No. 61/101,049 filed
`29 Sep. 2008, which application is hereby incorporated fully
`by reference.
`
`BACKGROUND OF THE INVENTION
`
`1. Field of the Invention
`
`The present invention relates generally to fabric systems,
`and more specifically to bed coverings constructed of high
`gauge circular knitted fabrics that accommodate and maintain
`optimum thermal conditions for sleep, which in turn can lead
`to faster sleep initiation and deeper, more restorative sleep.
`2. Description of Related Art
`Sleep problems in the United States are remarkably wide-
`spread, affecting roughly three out of four American adults,
`according to research by the National Sleep Foundation
`(NSF). Consequently, a great deal of attention has been paid
`to the circumstances surrounding poor sleep, along with strat-
`egies for how to improve it.
`The implications are not merely academic. Sleep—not
`only the right amount of it but also the right quality—impacts
`not just day-to-day performance, but also “the overall quality
`of our lives,” according to the NSF. Addressing the causes of
`poor quality sleep, therefore, has ramifications for millions.
`Though many factors contribute to sleep quality, the sleep
`environment itself plays a critical role, and sleep researchers
`routinely highlight temperature as one of the most important
`components in creating an environment for optimal sleep. As
`advised by the University of Maryland Medical Center, “a
`cool (not cold) bedroom is often the most conducive to sleep.”
`The National Sleep Foundation further notes that “tempera-
`tures above 75 degrees Fahrenheit and below 54 degrees will
`disrupt sleep,” with 65 degrees being the ideal sleep tempera-
`ture for most individuals, according to the NSF.
`A lower environmental temperature is not the only thermal
`factor associated with improved sleep. Researchers have
`noted a nightly drop in body temperature among healthy,
`normal adults during sleep. This natural cycle, when inhibited
`or not functioning properly, can disrupt sleep and delay sleep
`onset, according to medical researchers at Cornell University.
`Conversely, the researchers noted, a rapid decline in body
`temperature not only accelerates sleep onset but also “may
`facilitate an entry into the deeper stages of sleep.”
`Therefore, maintaining an appropriately cool sleep envi-
`ronment and accommodating the body’s natural tendency to
`cool itself at night should be a top priority for individuals
`interested in optimizing their sleep quality. Performance fab-
`rics crafted into bedding applications would be uniquely
`capable of promoting cool, comfortable—and therefore bet-
`ter—sleep, as these advanced fabrics maximize breathability
`and heat transfer. Performance fabrics are made for a variety
`of end-use applications, and can provide multiple functional
`qualities, such as moisture management, UV protection, anti-
`microbial, thermo-regulation, and wind/water resistance.
`There has been a long felt need in several industries to
`provide improved bedding to help individuals get better sleep.
`Such improved bedding would include beneficial wicking
`among other properties. For example, in marine, boating and
`recreational vehicle applications, bedding should resist mois-
`ture, fit odd-shaped mattresses and beds, and reduce mildew.
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`Particularly with watercraft, there is a need to protect bed-
`ding, and specifically sheets, from moisture and mildew accu-
`mulation.
`
`An additional problem with bedding, not just with marine
`and recreational vehicles, is the sticky, wet feeling that can
`occur when the bedding sheets are wet due to body sweat,
`environmental moisture, or other bodily fluids. In particular,
`when bedding is used during hot weather, or is continuously
`used for a long time by a person suffering from an illness,
`problems can arise in that the conventional bed sheet of cotton
`fiber or the like carmot sufficiently absorb the moisture. All of
`these issues lead to poor sleep.
`To date, performance fabric bedding products are not
`known. There are width limitations in the manufacturing of
`high gauge circular knit fabrics, because the finished width of
`bedding fabrics are dictated by the machine used in its con-
`struction. At present, performance fabrics are manufactured
`with a maximum width ofunder 90 inches wide, given present
`manufacturing and technical
`limitations, along with the
`inability of alternate manufacturing processes to produce a
`fabric with identical performance attributes. Yet, normal bed
`sheet panels can be 102 by 91 inches or larger. Thus, perfor-
`mance fabrics cannot yet be used for bed sheets.
`Some conventional solutions for the above issues that
`
`hinder a good night’s sleep include U.S. Pat. No. 4,648,186,
`which discloses an absorbent wood pulp cellulose fiber that is
`provided in a variety of sizes and is placed under a mattress.
`The wood pulp is water absorbent and acts to capture mois-
`ture to prevent such moisture from being retained by the
`bedding or the bedding sheets. However, this proposed solu-
`tion does not interact with the bedding or the bedding sheets,
`but merely acts as a sponge for moisture that is in proximity to
`the target bedding.
`U.S. Pat. No. 5,092,088 discloses a sheet-like mat com-
`prised of a mat cover, the inside of which is divided into a
`plurality of bag-like spaces, and a drying agent packed into a
`bag and contained in the bag-like spaces in such a manner that
`the drying agent carmot fall out of the bag-like spaces. A
`magnesium sulfate, a high polymer absorbent, a silica gel or
`the like can be used as the drying agent. As can be seen, this
`proposed solution to moisture in bedding is cumbersome and
`chemically-based.
`In the athletic apparel industry, moisture wicking fabric has
`beenused to construct athletic apparel. For example, U.S. Pat.
`No. 5,636,380 discloses a base fabric of CoolmaxQ high
`moisture evaporation fabric having one or more insulating
`panels of ThermaxB or ThermastatQ hollow core fiber fabric
`having moisture wicking capability and applied to the inner
`side of the garment for skin contact at selected areas of the
`body where muscle protection is desired. However, this appli-
`cation cannot be applied to bedding sheets due to the limita-
`tions of the size of the performance fabrics manufactured.
`Further, performance fabric such as this type cannot be easily
`stitched together as the denier is so fine that stitching this
`fabric results in the stitching simply falling apart.
`Circular knitting is typically used for athletic apparel. The
`process includes circularly knitting yams into fabrics. Circu-
`lar knitting is a form of weft knitting where the knitting
`needles are organized into a circular knitting bed. A cylinder
`rotates and interacts with a cam to move the needles recipro-
`cally for knitting action. The yams to be knitted are fed from
`packages to a carrier plate that directs the yarn strands to the
`needles. The circular fabric emerges from the knitting needles
`in a tubular form through the center of the cylinder. This
`process is described in U.S. Pat. No. 7,117,695. However, the
`machinery presently available for this method ofmanufacture
`can only produce a fabric with a maximum width of approxi-
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`US 8,566,982 B2
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`3
`mately 90 inches. Therefore, this process has not been known
`to manufacture sheets, since sheets can have dimensions of 91
`inches by 102 inches or greater.
`Further, the machinery that is used for bedding is very
`different than for athletic wear. For example, bedding manu-
`facturing equipment is not equipped to sew flatlock stitching
`or to provide circular knitting. Bed sheets typically are knit
`using a process known as warp knitting, a process capable of
`producing finished fabrics in the widths required for bedding.
`This method, however, cannot be employed to produce high-
`quality performance fabrics. Warp knitting is not capable of
`reproducing these fabrics’
`fine tactile qualities nor their
`omni-direction stretch properties, for example.
`Circular knitting must be employed to produce a perfor-
`mance fabric that retains these fabric’s full range of benefits
`and advantages. However, in order to produce a fabric of the
`proper width for bedding applications, a circular knit machine
`of at least 48 inches in diameter would be necessary. Manu-
`facturing limitations therefore preclude the construction of
`performance fabrics at proper widths for bedding. The indus-
`try is unsure if it could actually knit and then finish perfor-
`mance fabrics at these large sizes, even if the machinery were
`readily available.
`sewing factories are typically not
`Further,
`athletic
`equipped to sew and handle large pieces of fabrics so that
`equipment limitations do not allow for the manufacture of
`bedding sheets.
`What is needed, therefore, is a bedding system that utilizes
`performance fabrics and their beneficial properties,
`the
`design of which acknowledges and addresses limitations in
`the manufacture ofthese fabrics. It is to such a system that the
`present invention is primarily directed.
`
`BRIEF SUMMARY OF THE INVENTION
`
`Briefly described, in preferred form, the present invention
`is a high gauge circular knit fabric for use in bedding, and a
`method for manufacturing such bedding. The bedding fabric
`has superior performance properties, while allowing for
`manufacture by machinery presently available and in use. In
`order to achieve a finished width of the size needed to create
`
`sheet-sized performance fabric, a high gauge circular knit
`machine of at least 48 inches in diameter is necessary. And
`while warp knitting machines are available that can produce
`wider fabrics, this method will not provide a fabric with the
`tactile qualities required, nor provide a fabric with omni-
`directional stretch.
`
`In an exemplary embodiment, the present invention is a
`method of making a finished fabric comprising at least two
`discrete performance fabric portions, and joining at least two
`discrete performance fabric portions to form the finished
`fabric. Forming the at least two discrete performance fabric
`portions can comprise knitting at least two discrete perfor-
`mance fabric portions, and more preferably, circular knitting
`at least two discrete performance fabric portions. Joining the
`at least two discrete performance fabric portions to form the
`finished fabric can comprise stitching at least two discrete
`performance fabric portions together to form the finished
`fabric.
`
`The at least two discrete performance fabric portions can
`have different fabric characteristics. Fabric characteristics as
`
`used herein include, among other things, moisture manage-
`ment, UV protection, anti-microbial,
`thermo-regulation,
`wind resistance and water resistance.
`
`The finished fabric can be used in, among other applica-
`tions, residential settings, or in marine, boating and recre-
`ational vehicle environments.
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`The present sheets offer enhanced drape and comfort com-
`pared to traditional cotton bedding, and are as fine as silk, yet
`provide the benefits ofhigh elasticity and recovery along with
`superior breathability, body-heat
`transport, and moisture
`management as compared to traditional cotton bedding.
`Conventional fitted sheets can bunch and slide on standard
`mattress sizes. Furthermore, if the fitted bed sheets do not fit
`properly, they do not provide a smooth surface to lie on. The
`present invention overcomes these issues.
`The present high gauge circular knit fabrics stretch to fit
`and offer superior recovery on the mattress allowing the fab-
`ric to conform to fit the mattress without popping off the
`corners of the mattress or billowing. The performance fabric
`can include spandex, offers a better fit than conventional
`bedding products, can accommodate larger or smaller mat-
`tress sizes with a single size sheet, and can conform to mat-
`tresses with various odd dimensions.
`
`Spandex—or elastane—is a synthetic fiber known for its
`exceptional elasticity. It is stronger and more durable than
`rubber, its major non-synthetic competitor. It is a polyure-
`thane-polyurea copolymer that was invented by DuPont.
`“Spandex” is a generic name, and an anagram of the word
`“expands.” “Spandex” is
`the preferred name in North
`America; elsewhere it is referred to as “elastane.” The most
`famous brand name associated with spandex is Lycra, a trade-
`mark of Invista.
`
`The present high gauge circular knit fabric offers durability
`in reduced pilling and pulling when compared to other knit
`technologies, and offer reduced wrinkles and enhanced color
`steadfastness
`
`In a preferred embodiment, the present performance fabric
`can allow for a one-size fitted sheet that can actually fit two
`different size mattresses. For example, the full fitted sheet of
`the present invention can fit on both the full and queen size
`bed. The twin fitted sheet of the present invention will also fit
`an XL twin. In a boating application, the present invention can
`be produced to fit almost every custom boat mattress.
`Testing of the present invention conducted at the North
`Carolina State University (NCSU) Center for Research on
`Textile Protection and Comfort confirms that the present per-
`formance fabrics provide a cooler sleeping environment than
`cotton. Performance bedding was tested side-by-side with
`commercially available cotton bed sheets in a series of pro-
`cedures designed to measure each product’s heat- and mois-
`ture-transport properties, as well as warm/cool-to-touch ther-
`mal transport capabilities.
`Across all tests, the present performance fabrics in bedding
`outperformed cotton, demonstrating the performance fabric’ s
`superiority in establishing and maintaining thermal comfort
`during sleep. This advantage is evident to users from the very
`onset, as NCSU testing indicates that, on average, perfor-
`mance bedding of the present invention offers improved heat
`transfer upon initial contact with the skin, resulting in a
`cooler-to-the-touch feeling.
`During sleep, high gauge circular knit performance bed-
`ding of the present invention helps to maintain thermal com-
`fort by trapping less body heat and breathing better than
`cotton. Testing has demonstrated that performance bedding
`made out ofperformance fabrics transfers heat away from the
`body up to two times more effectively than cotton. This is
`critically important not only for sustained comfort during
`sleep, but also in terms of enabling the body to cool itself as
`rapidly as possible to facilitate sleep onset. In addition to
`trapping less heat, performance bedding breathes better than
`cotton—up to 50% better, giving performance bedding a
`strong advantage in terms of ventilation and heat and mois-
`ture transfer.
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`5
`The performance advantage over cotton holds true for
`simulated dry and wet skin conditions, confirming that certain
`performance fabrics in bedding are better suited than cotton at
`managing moisture (e. g., sweat) to maintain thermal comfort.
`In addition to wicking moisture away from the skin through
`capillary
`action,
`the performance
`fabric’s
`advanced
`breathability further enables heat and moisture transfer
`through evaporative cooling. As a result, the user is kept
`cooler, drier and more comfortable than with cotton.
`The present performance bedding holds a distinct advan-
`tage over cotton in enabling, accommodating and maintain-
`ing optimum thermal conditions for sleep, which in turn can
`lead to faster sleep initiation and deeper, more restorative
`sleep.
`These and other objects, features and advantages of the
`present invention will become more apparent upon reading
`the following specification in conjunction with the accompa-
`nying drawings.
`
`BRIEF DESCRIPTION OF THE FIGURES
`
`FIG. 1 illustrates a preferred embodiment of the present
`invention.
`
`FIG. 2 illustrates another preferred embodiment of the
`present invention.
`FIG. 3A illustrates a further preferred embodiment of the
`present invention.
`FIG. 3B illustrates pull ties useful with a preferred embodi-
`ment of the present invention.
`FIG. 3C illustrates a cinched pull tie of FIG. 3B.
`FIGS. 3D-3E illustrate stitching embodiments useful for
`securing portions of the present invention together.
`FIG. 4 illustrates another preferred embodiment of the
`present invention.
`
`DETAILED DESCRIPTION OF PREFERRED
`EMBODIMENTS
`
`Although preferred embodiments of the invention are
`explained in detail, it is to be understood that other embodi-
`ments are contemplated. Accordingly, it is not intended that
`the invention is limited in its scope to the details of construc-
`tion and arrangement ofcomponents set forth in the following
`description or illustrated in the drawings. The invention is
`capable of other embodiments and of being practiced or car-
`ried out in various ways. Also, in describing the preferred
`embodiments, specific terminology will be resorted to for the
`sake of clarity.
`It must also be noted that, as used in the specification and
`the appended claims, the singular forms “a,” “an” and “the”
`include plural referents unless the context clearly dictates
`otherwise. For example, reference to a sheet or portion is
`intended also to include the manufacturing of a plurality of
`sheets or portions. References to a sheet containing “a” con-
`stituent is intended to include other constituents in addition to
`the one named.
`
`Also, in describing the preferred embodiments, terminol-
`ogy will be resorted to for the sake ofclarity. It is intended that
`each term contemplates its broadest meaning as understood
`by those skilled in the art and includes all technical equiva-
`lents which operate in a similar manner to accomplish a
`similar purpose.
`Ranges may be expressed herein as from “about” or
`“approximately” one particular value and/or to “about” or
`“approximately” another particular value. When such a range
`is expressed, another embodiment includes from the one par-
`ticular value and/or to the other particular value.
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`By “comprising” or “containing” or “including” is meant
`that at least the named compound, element, particle, or
`method step is present
`in the composition or article or
`method, but does not exclude the presence of other com-
`pounds, materials, particles, method steps, even if the other
`such compounds, material, particles, method steps have the
`same function as what is named.
`It is also to be understood that the mention of one or more
`
`method steps does not preclude the presence of additional
`method steps or intervening method steps between those
`steps expressly identified. Similarly, it is also to be under-
`stood that the mention of one or more components in a fabric
`or system does not preclude the presence of additional com-
`ponents or intervening components between those compo-
`nents expressly identified.
`Referring now in detail to the drawing figures, wherein like
`reference numerals represent like parts throughout the several
`views, the present invention of FIGS. 1 and 4 provides a sheet
`10 shown having dimensions of 102 inches in length and 91
`inches in width. The material is manufactured from perfor-
`mance fabric, which can include,
`for example, varying
`amounts of one or more of Lycra, Coolmax, Thermax and
`Thermastat. In a preferred embodiment, the fabric is treated
`so that the fabric has antimicrobial properties. By using cir-
`cular-knit performance fabric, the fabric is able to provide
`elasticity in all four directions. This property allows for the
`sheet to fit extraordinary mattress, cushion and bedding
`shapes, as well as providing better fits for traditional rectan-
`gular sheets. By using performance fabrics, the sheet has
`elastic properties that allow stretching in the directions shown
`as 30. In addition, by using circular-knit performance fabric,
`the resulting bedding retains an exceptionally fine tactile
`quality critical for providing maximum levels of enhanced
`comfort.
`
`An alternative to circular knitting is non-circular knit-
`ting—for example, warp knitting. This method can achieve
`widths greater than circular knitting. Industrial warp knit
`machines, for example, can produce tricote warp knit fabrics
`up to 130-140 inches in width. Circular knitting, however, is
`less expensive, as it requires less set-up time. Circular knit-
`ting also provides greater multidirectional stretch.
`In order to provide a sheet that exceeds the maximum
`dimensions of fabric that can be produced by available circu-
`lar knitting machines, flat lock stitching 12 is used to join a
`plurality of portions resulting in a sheet that is 91 inches wide
`(as shown). In an exemplary embodiment, piping 11 can be
`included in close proximity to the stitching. The stitching can
`be the same color as the fabric of the sheet portions, or
`different color(s). The piping can be 3/4 inch straight piping
`without a cord or other filler. In one preferred embodiment,
`the stitching is 16 stitches per inch. Piping 11 can be included
`at one end ofthe sheet and can be the same or a different color
`as the sheet fabric.
`
`For a fitted sheet, the sheet can include an elastic portion
`surrounding the edge ofthe fitted sheet to better keep the fitted
`sheet in place when placed on a mattress or other sleeping
`surface. A cord can be sewn into the edge of the fitted sheet
`and cinched around the mattress or other sleeping surface to
`better hold the fitted sheet in place.
`Referring to FIG. 2, a sheet is shown having dimensions of
`91 inches wide and 102 inches in length. In this embodiment,
`stitching 14 is shown 34 inches from an interior edge 18 of a
`main portion 16 and another stitch 14 at edge 20 of the
`sewn-on portion. Flat lock stitching can be used for the stitch-
`ing. Piping can be applied at or in proximity to the stitching.
`Referring to FIGS. 3A-E, a non-rectangular shaped sheet is
`shown in FIG. 3A. In this exemplary embodiment, elastic can
`
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`US 8,566,982 B2
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`7
`be included around the edge of the fitted sheet to better main-
`tain the fitted sheet in position when placed on a sleeping
`surface. In one embodiment, pull ties 24 (FIG. 3B) can be
`installed at various locations around the edge of the fitted
`sheet in order to assist in maintaining the fitted sheet secured
`to the sleeping surface. The pull tie can be cinched to increase
`tension around the edge of the fitted sheet as shown by 26
`(FIG. 3C).
`Stitching used for securing the portions of the sheet
`together can include that shown in FIGS. 3D-3E, for example
`as 2811. In another embodiment, the stitching used for secur-
`ing the portion of fabric together is shown as 28b.
`Referring to FIG. 4, yet another preferred embodiment of
`the invention is shown. In this embodiment, the sheet can be
`assembled through stitching of differing fabrics for generat-
`ing performance zones in the sheet. For example, zone 32 can
`have higher wicking properties than the other zones since this
`area is where the majority of the individual body rests. Areas
`34a through 34d can have higher spandex or other elastic
`fabric properties so that the fit around a sleeping surface is
`improved. Area 36 may have thermal properties such as
`increased cooling since this area is generally where the indi-
`vidual’s head lies. In an exemplary embodiment, the pillow
`covers of pillows used by the individual also have differing
`properties from the remainder ofthe sheet, e.g., thermal prop-
`erties.
`
`The present invention encompasses the construction of
`bedding materials that have superior performance properties
`while allowing for manufacture by machinery presently
`available and inuse. More specifically, the invention is related
`to a new method for fabricating a covering and or sheets in
`bedding. When using the circular knitting machine, the high
`gauge performance fabrics can only be made to a maximum
`size of 72.5 inches without losing the integrity ofthe spandex
`in the fabric.Yet, normal sheet panels are l02><9l inches. This
`presents problems when manufacturing sheets from perfor-
`mance fabrics.
`
`Additionally, special stitching techniques must be used
`given the thread density of the fabric. Using this special
`stitching, panels are sewn together to produce bedding or a
`sheet that is the proper size for standard bed sheets. Because
`discrete portions/panels are used in the manufacture of the
`present fabrics, panels can be selected that provide different
`properties for different areas of the bedding (FIG. 4). Stitch-
`ing or seams on the sheet can also allow for the ease ofmaking
`the bed. Because the bedding is made from performance
`fabric with spandex, it stretches to permit multiple and cus-
`tom sizing for applications in cribs, recreational vehicles and
`boats.
`
`Circular knitting machines used for high gauge perfor-
`mance bedding fabrics are called high-gauge circular knitting
`machines, because of dense knitting with thin yarn. High
`gauge generally denotes 17 gauges or more. Seventeen
`gauges indicate that 17 or more cylinder needles are con-
`tained in one inch. Circular knitting machines of less than 17
`gauges are referred to as
`low-gauge circular knitting
`machines. The low-gauge circular knitting machines are
`often used to knit outerwear.
`
`“Yam count” indicates the linear density (yarn diameter or
`fineness) to which that particular yarn has been spun. The
`choice of yarn count is restricted by the type of knitting
`machine employed and the knitting construction. The yarn
`count, in turn, influences the cost, weight, opacity, hand and
`drape ofthe resulting knitted structure. In general, staple spun
`yarns tend to be comparatively more expensive the finer their
`
`10
`
`15
`
`20
`
`25
`
`30
`
`35
`
`40
`
`45
`
`50
`
`55
`
`60
`
`65
`
`8
`count, because finer fibers and a more exacting spinning
`process are necessary in order to prevent the yarn from show-
`ing an irregular appearance.
`A top width in the 90-inch range is currently possible using
`a circular knit fabric formed on a 36-38-inch diameter
`
`machine, although higher levels of spandex in the perfor-
`mance fabric tend to pull the width in. Injust one example, on
`a 30-inch diameter machine, the spandex can reduce an oth-
`erwise 94-inch circumference fabric tube to one with a 60-65
`inch finished width.
`
`A major limitation in finished width is not strictly a knitting
`concern but also concerns finishing. With performance fabric,
`it tends to sag in the middle—increasingly so with greater
`widths—making finishing difficult to impossible above a cer-
`tain threshold. Apossible 90-inch finished width is contingent
`upon having a good finishing set-up capable of handling the
`present performance fabric. This potential for difficulties
`would only become compounded at the larger widths required
`for bed sheets.
`
`In a preferred process, the present fabric undergoes a heat
`setting finishing process. Applying a moisture-wicking finish
`to another fabric—like cotton—that can be produced at larger
`widths appears unlikely to match the moisture-control prop-
`erties of the present fabric, as polyester itself is naturally
`moisture-resistant and there are physical actions (e.g. capil-
`lary ac