US20170196382A1

US20170196382A1 - Percale Bedding System

Info

Publication number: US20170196382A1
Application number: US15/467,207
Authority: US
Inventors: Kamal Garg; Gagan Rai
Original assignee: Individual
Current assignee: Individual
Priority date: 2015-03-25
Filing date: 2017-03-23
Publication date: 2017-07-13

Abstract

Percale weave sheeting has warp yarn and weft yarn. The percale weave sheeting has two surfaces. Both surfaces exhibit color consistency. The warp yarn and the weft yarn are a cross weave of cotton and polyester.

Description

RELATED APPLICATIONS

The present application is a continuation-in-part of pending U.S. application Ser. No. 15/288,263 filed Oct. 7, 2016, which is a continuation-in-part of pending U.S. application Ser. No. 14/828,868 filed Aug. 18, 2015, which is a continuation-in-part of abandoned U.S. application Ser. No. 14/698,466 filed Apr. 28, 2015, which is a continuation-in-part of abandoned U.S. application Ser. No. 14/668,124 filed Mar. 25, 2015, the subject matter of which applications is incorporated herein by reference and the priority of which is hereby claimed.

BACKGROUND OF THE INVENTION

Field of the Invention
The present invention relates to a percale bedding system and more particularly pertains to bedding fabricated of a percale fabric characterized by anti-wrinkle capabilities, increased softness and increased durability/long life, and decreased cost.
Description of the Prior Art
The use of bedding fabric of known designs and configurations is known in the prior art. More specifically, bedding fabric of known designs and configurations previously devised and utilized for the purpose of fabricating bedding are known to consist basically of familiar, expected, and obvious structural configurations, notwithstanding the myriad of designs encompassed by the crowded prior art which has been developed for the fulfillment of countless objectives and requirements.
While the prior art fabrics fulfill their respective, particular objectives and requirements, they do not describe a percale bedding system that is characterized by anti-wrinkle capabilities, increased softness and increased durability/long life, and decreased cost.
In this respect, the percale bedding system according to the present invention substantially departs from the conventional concepts and designs of the prior art, and in doing so provides a fabric weave primarily developed for the purpose of fabricating bedding of a percale fabric characterized by anti-wrinkle capabilities, increased softness and increased durability/long life, and decreased cost.
Therefore, it can be appreciated that there exists a continuing need for a new and improved percale bedding system which can be used for fabricating bedding of a percale fabric characterized by anti-wrinkle capabilities, increased softness and increased durability/long life, and decreased cost. In this regard, the present invention substantially fulfills this need.

SUMMARY OF THE INVENTION

In view of the foregoing disadvantages inherent in the types of bedding fabric of known designs and configurations now present in the prior art, the present invention provides an improved percale bedding system. As such, the general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new and improved percale bedding system and method which has all the advantages of the prior art and none of the disadvantages.
To attain this, the present invention broadly is fabric fabricated of percale weave sheeting. The sheeting has warp yarn and weft yarn. The warp yarn and the weft yarn are a cross weave of cotton and polyester.
There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood and in order that the present contribution to the art maybe better appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims attached.
In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of descriptions and should not be regarded as limiting.
As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
It is therefore an object of the present invention to provide a new and improved percale bedding system which has all of the advantages of the prior art bedding fabric of known designs and configurations and none of the disadvantages.
It is another object of the present invention to provide a new and improved percale bedding system which may be easily and efficiently manufactured and marketed.
It is a further object of the present invention to provide a new and improved percale bedding system which is of durable and reliable constructions.
An even further object of the present invention is to provide a new and improved percale bedding system which is susceptible of a low cost of manufacture with regard to both materials and labor, and which accordingly is then susceptible of low prices of sale to the consuming public, thereby making such percale bedding system economically available to the buying public.
Lastly, it is an object of the present invention to provide a new and improved bedding system fabricated of a percale fabric characterized by anti-wrinkle capabilities, increased softness and increased durability/long life, and decreased cost.
These together with other objects of the invention, along with the various features of novelty which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated preferred embodiments of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:

FIG. 1 is a perspective illustration of a percale bedding system fabricated in accordance with the principles of the present invention.

FIG. 2 is a front elevational view of the top sheet and pillow cases of FIG. 1.

FIG. 3 is front elevational view of the fitted sheet of FIG. 1.

FIG. 4 is an enlarged front elevational view of the fabric of the bedding of the prior Figures.

FIG. 5 is a graph charting 15 denier to 240 denier polyester filament yarn against 140 thread count to 1200 thread count threads per inch of cotton rich grid.

FIG. 6 is a graph charting 15 denier to 240 denier polyester filament yarn against 140 thread count to 1200 thread count threads per inch and measuring tensile strength.

FIG. 7 is a graph charting 15 denier to 240 denier polyester filament yarn against 140 thread count to 1200 thread count threads per inch and measuring fabric increased durability grid.

The same reference numerals refer to the same parts throughout the various Figures.

DESCRIPTION OF THE PREFERRED EMBODIMENT

With reference now to the drawings, and in particular to FIG. 1 thereof, the preferred embodiment of the new and improved percale bedding system embodying the principles and concepts of the present invention and generally designated by the reference numeral 10 will be described.
The present invention, the percale bedding system 10 is comprised of a plurality of components. Such components in their broadest context include percale weave sheeting having warp yarn and weft yarn, the warp yarn and the weft yarn being a cross weave of cotton and polyester.
In the preferred embodiment, bedding 10 is characterized by anti-wrinkle capabilities, increased softness and increased durability/long life, and decreased cost. The bedding is fabricated of percale weave sheeting. The percale weave sheeting has two surfaces wherein both surfaces exhibit color consistency. The bedding includes one, two, or four pillow cases 12, a top sheet 14, and a fitted sheet 16.
The percale weave sheeting has cotton warp yarn 18 with a denier of 10 D to 240 D with 14 to 216 filament thread count. The cotton warp yarn has a thread count of 30 s to 60 s. The cotton warp yarn is a rich chief value cotton, CVC, with a 51 percent minimum of cotton and a 49 percent maximum of polyester/filament yarn, or polyester spun yarn, or polyester cotton spun yarn.
The percale weave sheeting has polyester weft yarn 20 with a denier of 10 D to 240 D. The polyester weft yarn is polyester filament, low intermingle. The polyester weft yarn is 14 filament to 216 filament thread count thereby providing improved crispness.
The percale weave sheeting has 130 to 2000 threads per square inch. The percale weave sheeting has a weight of 80 to 250 grams per square inch thereby exhibiting high tensile strength.
The cotton warp yarn and the polyester weft yarn in each surface are in across weave, 1/1, 1 over 1 and under. The warp and weft, which are preferably cotton and polyester, may be interchanged to polyester warp and cotton weft whereby both surfaces comprise a proportion of cotton and a proportion of polyester, the proportion of cotton being greater than the proportion of polyester.
In alternate embodiments, the fabric is formed as a pillowcase, a top sheet, or a fitted sheet. In another alternate embodiment, the bedding includes pillowcases, a top sheet, and a fitted sheet.
In a further alternate embodiment, the cross weave is 1/1, 1 over and 1 under. In another embodiment, the cross weave is 1 over and 2 under. In still another embodiment, the cross weave is ¼, 1 over and 4 under.
The present invention is percale sheeting manufactured into fine products including luxury percale bed sheets, fitted sheets and pillow cases. Such products are characterized by a percale weave construction 1/1, 1 up 1 down, of a high thread count of at least about 130 threads per square inch to 2000 threads per square inch thereby exhibiting low pilling. Prior art percale sheets were either from 100 percent cotton or cotton with polyester filament yarn/polyester or spun yarn/polyester or cotton spun yarn. The sheeting of the present invention is chief value cotton, CVC, that is predominant cotton with the cotton comprising a minimum of 51 percent over polyester filament yarn/polyester spun yarn/polyester cotton spun yarn which will be a maximum 49 percent. The cotton yarn count can vary from 30 s to 60 s thread count and polyester filament yarn/polyester or spun yarn/polyester cotton spun yarn which can vary from 10 D up to 240 D with 14 filament to 216 filament thread count.
The polyester fibers were included in the prior art cotton percale because of the cost of the polyester yarn which was much cheaper than the cotton yarn. Hence, a product with polyester will be cheaper for the consumer, value for money in the hands of the consumer.
The polyester-cotton fabric of the present invention gives wrinkle resistance. Moreover, polyester yarn is known for its increased durability adding to the tensile strength, increased durability, dimensional stability, wear and tear performance of the fabric of the present invention thereby making it more attractive for the consumer.
Sheeting fabrics suitable for use in the present invention are of a plain weave construction with a thread count of at least about 130 threads per inch up to 2000 threads per inch. Cotton yarn count from 30 s to 60 s with 10 denier to 240 denier with 14 filaments to 216 filament, and typically have a weight range of about 80 grams per square meter to 250 grams per square meter thereby exhibiting high tensile strength. They are generally of a substantially balanced construction. The percale weave is a closed construction and is balanced with warp and weft.
The sheeting fabric in accordance with the present invention comprises a woven percale sheeting fabric having a uniform woven fabric construction of at least 130 thread count per inch up to 1200 threads per inch throughout both the sheet areas and the heavier areas. The core spun yarns have a yarn count of about 30 s to 60 s in cotton and 10 D D to 240 D of filament polyester/polyester spun yarn/polyester cotton spun yarn.
Percale sheeting fabric can be formed of a single common color, or different colors, or of multiple colors by incorporating into the print, in addition to the oxidizing agent, suitable disperse dyestuffs which sublime into the polyester core component. Polyester dyed is in disperse dyeing and cotton in reactive dyeing to match both components of fabric and the print will be in pigment dyes.
Cotton yarn will be from 30 s to 60 s yarn count made from either carded/combed/compact or Egyptian/pima/supima cotton. Percale fabric is woven with warp cotton yarn 100 percent cotton/Egyptian cotton/pima/supima cotton and weft polyester filament yarn/polyester spun yarn/polyester cotton spun yarn. In the alternative, it can be either way with warp polyester filament yarn/polyester spun yarn/polyester cotton spun yarn and weft cotton yarn 100 percent cotton/Egyptian cotton/pima/supima cotton.
In addition polyester filament yarn, polyester spun yarn and polyester cotton spun yarn are added. The polyester filament yarn may also be CVC.
FIG. 5 is a graph charting 15 denier to 240 denier polyester filament yarn against 140 thread count to 1200 thread count threads per inch of cotton rich grid. This graph demonstrates that the sweet spot is 60 percent cotton and is based on the test method AATCC 20 and 20A.
FIG. 6 is a graph charting 15 denier to 240 denier polyester filament yarn against 140 thread count to 1200 thread count threads per inch and measuring tensile strength. This graph demonstrates that the tensile strength sweet spot is 40 lbs by 40 lbs for both weft and warp as per ASTM 5034 test method.
FIG. 7 is a graph charting 15 denier to 240 denier polyester filament yarn against 140 thread count to 1200 thread count threads per inch and measuring fabric pilling grid. This graph demonstrates that the sweet spot in this test is grade 4.0 as per ASTM D4970 (100 Movement).
Note is taken of a comparison between the CVC bedding of the present invention and conventional satin CVC bedding.
a) The cotton content is more in percale weave than in satin weave, as in satin weave it is 4/1. The present invention has cotton only on the top surface and the bottom is 100 percent polyester, where in percale it is 1/1 weave so the cotton portion is there on both surfaces so percale bedding is better.
b) The tensile strength is more in percale versus satin.
c) As both surfaces are the same in the present invention, the color consistency will be much higher and even in percale as compared to satin.
d) There is also more crispness in the present invention since cotton is present on both sides in percale vs. satin.
e) Pilling is less and washing is better in percale versus satin as both surfaces are the same.
As to the manner of usage. and operation of the present invention, the same should be apparent from the above description. Accordingly, no further discussion relating to the manner of usage and operation will be provided.
With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
Therefore, the foregoing is considered as illustrative only, of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable Modifications and equivalents may be resorted to, falling within the scope of the invention.

Claims

What is claimed as being new and desired to be protected by Letters Patent of the United States is as follows:

1. Fabric fabricated of percale weave sheeting, the percale weave sheeting having two surfaces wherein both surfaces-exhibit color consistency, the percale weave sheeting having warp yarn and weft yarn, the warp yarn and the weft yarn being a cross weave of cotton and polyester.

2. The fabric as set forth in claim 1 wherein the percale weave sheeting is formed as a pillowcase.

3. The fabric as set forth in claim 1 wherein the percale weave sheeting is formed as a top sheet.

4. The fabric as set forth in claim 1 wherein the percale weave sheeting is formed as a fitted sheet.

5. The fabric as set forth in claim 1 wherein the percale weave sheeting is formed as pillowcases, a top sheet, and a fitted sheet.

6. The fabric as set forth in claim 1 wherein the warp yarn is cotton, 10 D D to 240 D denier and 30 s to 60 s thread count.

7. The fabric as set forth in claim 6 wherein the cotton is chief value cotton with a minimum of 51 percent cotton and 49 percent chosen from polyester/filament yarn and polyester spun yarn and cotton spun yarn.

8. The fabric as set forth in claim 1 wherein the weft yarn is polyester filament, low intermingle, 10 D D to 240 D denier and 14 filament to 36 filament thread count.

9. The fabric as set forth in claim 1 wherein the weft yarn is polyester filament, low intermingle, 10 D D to 240 D denier and 36 filament to 72 filament thread count.

10. The fabric as set forth in claim 1 wherein the weft yarn is polyester filament, low intermingle, 10 D D to 240 D denier and 72 filament to 108 filament thread count.

11. The fabric as set forth in claim 1 wherein the warp yarn is cotton filament, with a yarn count of 30 to 60 s, and 15 D to 240 D denier, and 14 to 216 filament, and wherein the weft yarn is polyester filament, low intermingled, 10 D D to 240 D denier and 14 to 216 filament thereby providing improved crispness.

12. The fabric as set forth in claim 1 wherein the cross weave is 1/1, 1 over and 1 under, whereby both surfaces comprise a proportion of cotton and a proportion of polyester, the proportion of cotton being greater than the proportion of polyester.

13. The fabric as set forth in claim 1 wherein the cross weave is ½, 1 over and 2 under.

14. The fabric as set forth in claim 1 wherein the cross weave is ¼, 1 over and 4 under.

15. The fabric as set forth in claim 1 wherein with the sheeting has a high thread count of from 130 threads per inch to 00 threads per inch.

16. The fabric as set forth in claim 1 wherein with the sheeting has a high thread count of from 300 threads per inch to 600 threads per inch.

17. The fabric as set forth in claim 1 wherein with the sheeting has a high thread count of from 600 threads per inch to 800 threads per inch.

18. The fabric as set forth in claim 1 wherein with the sheeting has a high thread count of from 800 to 2000 threads per inch thereby exhibiting low pilling.

19. The fabric as set forth in claim 1 wherein the sheeting has a weight range of 80 to 250 grams per square meter thereby exhibiting high tensile strength.