Note: Descriptions are shown in the official language in which they were submitted.
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FABRIC MATERIAL
Cross-Reference to Related Application
The present application claims the benefit of U.S. Provisional Patent
Application
Serial No. 61/555,581 filed on November 4, 2011 entitled FABRIC FOR BED SHEET,
the disclosure of which is incorporated herein by reference in its entirety.
Technical Field of the Invention
The present invention relates to fabric material, and, more particularly, to
fabric
material having antimicrobial and healing properties, as well as a low
coefficient of
friction,
Background Art
Products made from fabric materials, such as bed sheets and pillow cases used
in hospitals, nursing homes and rehabilitation centers, are a potential source
of bacterial
colonization, skin irritation, and migration or worsening of skin infections.
Bed sheets
and pillow cases often produce irritated areas on a patient's skin as a result
of friction
caused by motion or lack of motion of the patient relative to the bed sheets
and pillow
cases. This skin irritation contributes to the formation of pressure ulcers.
What is
needed is a fabric material having antimicrobial properties, a low coefficient
of friction, a
"cool to the touch" feel, and moisture-wicking properties.
Disclosure of the Invention
In an embodiment, a fabric material including a plurality of strands of a warp
yarn
positioned in a warp direction; a plurality of strands of a first filling yarn
positioned in a
filling direction, each of the plurality of strands of the first filling yarn
being impregnated
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by silver ions; and a plurality of strands of a second filling yarn positioned
in the filling
direction each of the plurality of strands of the second filling yarn being
impregnated by
copper ions, wherein the plurality of strands of the warp yarn are woven with
the
plurality of strands of the first filling yarn and the plurality of strands of
the second filling
yarn to form a face side and a back side opposite the face side, and wherein
each of the
plurality of stands of the first filling yarn and each of the plurality of
strands of the
second filling yarn are woven alternately relative to one another with the
plurality of
strands of the warp yarn in the filling direction.
In an embodiment, the fabric material includes a five-harness satin weave
pattern. In an embodiment, the five-harness satin weave pattern is
characterized by
two of the plurality of strands of the first filling yarn and two of the
plurality of strands of
the second filling yarn floating over four of the plurality of strands of the
warp yarn on
the face side. In an embodiment, the five-harness satin weave pattern is
characterized
by four strands of the plurality of strands of the warp yarn underlying two
strands of the
plurality of strands of the first filling yarn and two strands of the
plurality of strands of the
second filling yarn on the back side. In an embodiment, the coefficient of
friction of the
face side in the filling direction is less than the coefficient of friction of
the back side in
the filling direction. In an embodiment, the plurality of strands of the warp
yarn are
made of filament rayon. In an embodiment, the plurality of strands of the
first filling yarn
are made from PLA polymer, and the plurality of strands of the second filling
yarn are
made from PLA polymer. In an embodiment, the fabric material is antimicrobial,
cool to
the touch, and wickable. In an embodiment, the plurality of strands of the
first filling
yarn are made from nylon, and the plurality of strands of the second filling
yarn are
made from nylon. In an embodiment, the plurality of strands of the first
filling yarn are
made from polyester, and the plurality of strands of the second filling yarn
are made
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from polyester.
In an embodiment, the fabric material is adapted to be used as a bed sheet. In
an embodiment, the fabric material includes a plain weave pattern. In an
embodiment,
the plain weave pattern is characterized by five strands of the plurality of
strands of the
warp yarn in the warp direction, and five alternating strands of the plurality
of strands of
the first filling yarn and the plurality of strands of the second filling yarn
in the filling
direction. In an embodiment, the coefficient of friction of the face side is
approximately
equal to the coefficient of friction of the back side. In an embodiment, the
fabric material
is adapted to be used as a pillow case. In an embodiment, the fabric material
includes
a twill pattern.
In an embodiment, a method for making a fabric material includes the steps of
weaving a plurality of strands of a warp yarn in a warp direction with a
plurality of
strands of a first filling yarn impregnated with silver ions in a filling
direction and a
plurality of strands of a second filling yarn impregnated with copper ions in
the filling
direction, wherein each of the plurality of stands of the first filling yarn
and each of the
plurality of strands of the second filling yarn are alternately woven with the
plurality of
strands of the warp yarn in the filling direction; scouring the fabric
material to remove
external matter; conditioning the fabric material in order to soften it;
drying the fabric
material; and calendaring the fabric material to smoothen it. In an
embodiment, the
conditioning step includes wet processing the fabric material using a cationic
softener.
In an embodiment, the silver ion impregnated filling yarn and the copper ion
impregnated filling yarn are manufactured separately and inserted alternately
in the
filling direction of the weave. In an embodiment, the silver and copper ions
of the filling
yarns provide antimicrobial and healing properties which are effective in
combating the
growth and proliferation of harmful bacteria and fungus. With the silver and
copper ions
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being inherently impregnated, they are resistant to being removed during
repeated
launderings of the fabric material, which enables the fabric's antimicrobial
and healing
properties to remain effective.
In an embodiment, the weave of the fabric material provides a low coefficient
of
friction on the face-side of the fabric, which inhibits irritation of a user's
skin. In an
embodiment, the rayon used in the warp direction of the weave possesses a low
coefficient of friction that reduces the level of friction experienced by a
user (such as a
patient on a bed sheet) when he/she moves from side-to-side relative to the
fabric. The
reduced level of friction inhibits the formation of skin abrasions, which is
one of the
causes of pressure ulcers. In an embodiment, the fabric material includes a
higher
coefficient of friction on the back-side thereof versus the coefficient of
friction on the
face-side thereof. The higher coefficient on the back-side inhibits movement
of the
fabric material during movement by the user, when he/she moves from side-to-
side
thereon, thus reducing formation of wrinkles and creases that causes
irregularity in the
fabric's surface and creates additional friction points for the user.
In an embodiment, the fabric material is used for medical bed sheets, pillow
cases, and other pressure ulcer related medical products. In an embodiment,
the fabric
material is absorbent and possesses a low coefficient of friction. In an
embodiment,
medical bed sheets that are fabricated from the fabric material provide
patients comfort
and pressure ulcer mitigation. Mitigation of patient pressure ulcers provides
a benefit to
the overall medical treatment and well being of the patient In an embodiment,
the low
coefficient of friction on the face-side of the bed sheet greatly enhances
rotation of
disabled or sedentary patients by hospital staff. In an embodiment, the fabric
material
helps support a significantly enhanced ergonomic process in the hospital
environment
(e.g., it facilitates patient movement and rotations by hospital care giver
staff). In an
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embodiment, the reduction in the required physical demands on care giver staff
not only
reduces lost time to injuries but also tends to increase the actual number of
patient
rotations completed by care givers. If patient rotations are easier to
accomplish, care
givers may be far more physically-able to complete timed rotations of the
patients.
In other embodiments, the fabric can be used in connection with wearing
apparel,
boots, elbow pads, and other contact point protection shields.
Brief Description of the Drawings
For a more complete understanding of the present invention, reference is made
to the following detailed description of an exemplary embodiment considered in
conjunction with the accompanying drawings, in which:
FIG. 1 is a diagrammatic plan view of a portion of a fabric material
constructed in accordance with an embodiment of the present invention, the
fabric
material being woven with yarn provided in a warp direction and two different
yarns
alternately provided in a filling or weft direction;
FIG. 2 is a cross-sectional view, taken along the line 2-2 and looking in the
direction of the arrows, of the fabric material shown in FIG. 1;
FIG. 3 is a top perspective view of a fitted bed sheet which is fitted on a
mattress, the sheet being made from the fabric material shown in FIGS. 1 and
2; and
FIG. 4 is a diagrammatic plan view of a fabric material constructed in
accordance with another embodiment of the present invention.
Best Mode for Carrying Out the Invention
Although the present invention can be used in conjunction with a fabric
material
for use with any type of sleeping or resting facility, it is particularly
suitable for bed
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sheets used in hospitals, medical facilities, and nursing homes. Accordingly,
the
present invention will be described hereinafter in connection with bed sheets
used in
hospitals, medical facilities, and nursing homes. It should be understood,
however, that
the following description is only meant to be illustrative of the present
invention and is
not meant to limit the scope of the present invention, which also has
applicability in
other facilities (e.g., hotels, etc.) or for other products, such as pillow
cases, wearing
apparel and clothing, boots and other footwear, elbow and knee pads, and other
fabric
protective guards and shields.
FIGS. 1 and 2 illustrate a portion of a fabric material 10 constructed in
1.0 accordance with an embodiment of the present invention. In embodiments
to be
described hereinbelow, the fabric material 10 is made from a plain weave, a
twill weave,
or a satin weave. In an embodiment, the fabric material 10 includes a face-
side 12 and
a back-side 14 opposite the face-side 12 (see FIG. 2). In an embodiment, the
fabric
material 10 is woven in a five-harness filling satin weave construction. FIG.
1 illustrates
the face-side 12 of the fabric material 10, which shows one of a repeating
pattern of a
plurality of strands of warp yarn 16 which are provided in a warp direction,
as indicated
by arrows W, and one of a repeating pattern of a plurality of alternating
strands of filling
yarn 18 and filling yarn 20, which are provided in the filling or weft
direction, as indicated
by arrows F. In an embodiment, the repeating pattern of the plurality of
strands of the
warp yarn 16 is five (5) strands, as shown in FIGS. 1 and 2. In an embodiment,
the
repeating pattern of the plurality of alternating strands of the filling yarns
18, 20 are five
(5) strands, as shown in FIG. 1. In an embodiment, the warp yarn 16 is made of
filament rayon. In an embodiment, the filament rayon comprises ENKA filament
rayon. In an embodiment, the filament rayon has a low coefficient of friction,
absorbency, wicking, and "cool to the touch" properties, and mitigates static
electricity.
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In other embodiments, the filament rayon can be made by other manufacturers.
In an embodiment, the strands of the filling yarn 18 are made from a PLA
(polyiactic acid) polymer, nylon or a polyester yarn base that is inherently
impregnated
with silver ions (i.e., impregnated substantially equally throughout the
entire yarn), while
the strands of filling yarn 20 provided in the filling direction F are made
from a PLA
polymer, nylon or a polyester yarn base that is inherently impregnated with
copper ions.
In an embodiment, the PLA polymer is manufactured by Radio' Fibers. In other
embodiments, the PLA polymer can be made by other manufacturers. In an
embodiment, the strands of the filling yarns 18, 20 are alternately inserted
in the filling
1.0 direction F (i.e., the filling yarn 20 is inserted in one pick,
alternating with the filling yarn
18 in the next pick, and so on). In an embodiment, the silver and copper ions
of the
filling yarns 18, 20 include antimicrobial and healing properties which are
described
hereinbelow.
In an embodiment, the filling yarn 18 is fabricated from fibers having
inherent
silver ions added to the base material of the master batch (e.g., PLA polymer,
nylon or
polyester yarn) of the fiber slurry in a process such as that disclosed in
International
Patent Publication Number WO 2006/084411 Al, published on August 17, 2006 (the
'411 International Publication), which is incorporated by reference herein in
its entirety.
Upon extrusion of the fiber, the silver ions are inherently part of the fiber.
Likewise, the
filling yarn 20 may be fabricated from fibers which have inherent copper ions
added to
the base material (e.g., PLA polymer, nylon or polyester yarn) of the master
batch of the
fiber slurry in the process disclosed in the '411 International Publication.
Upon
extrusion of the fiber, the copper ions are inherently part of the fiber.
In an embodiment, FIG. 2 illustrates the surface contours of the face-side 12
and
the back-side 14 of the five-harness filling satin weave construction of the
fabric material
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10, In an embodiment, an arrow L indicates one of a repeated area of surface
contours
on the face-side 12, which contributes to a coefficient of friction in the
filling direction F
that is lower than the coefficient of friction in the filling direction F on
the back-side 14 of
the fabric material 10. More particularly, in an embodiment, on the face-side
12 of the
fabric, an arrow L indicates one of a repeated area of surface contours in
which the two
strands of the filling yarn 18 and the two strands of the filling yarn 20
float over (i.e., is
not interwoven with) four strands of the warp yarn 16, thereby minimizing the
coefficient
of friction on the face-side 12 in the filling direction F. In an embodiment,
the rayon
used in the warp direction W also contributes to the low coefficient of
friction in the filling
direction F. In an embodiment, on the back-side 14 of the fabric material 10,
an arrow H
indicates one of a repeated area of surface contours in which the four strands
of the
warp yarn 16 underlie the two strands of the filling yarn 18 and the two
strands of the
filling yarn 20, thereby maximizing the coefficient of friction on the back-
side 14 in the
filling direction F.
In an embodiment, the fabric 10 is woven in specific shapes and sizes to
accommodate end use applications. For example, in an embodiment illustrated by
FIG.
3, a fitted bed sheet 22, which is made of the fabric material 10 and has
fitted bottoms
corners C, is shown fitted on a bed mattress 24, In an embodiment, a pillow 26
is also
shown positioned on the fitted bed sheet 22. In an embodiment, the mattress 24
has a
length indicated by the arrow L, a breadth indicated by the arrow B, and a
thickness
indicted by the arrow T. In an embodiment, the coefficient of friction in the
filling
direction F of the fabric material 10 reduces the level of friction that is
experienced by a
person (e.g., a patient) when he/she moves from side-to-side or is rotated by
care giver
staff on the face-side 12 of the fitted bed sheet 22. In an embodiment, the
reduced level
of friction on the face-side 12 of the fabric material 10 inhibits the
formation of skin
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abrasions on the skin of the person resting on the fitted bed sheet 22, which
is one of
the causes of pressure ulcers. In an embodiment, the higher coefficient of
friction of the
back-side 14 of the fitted bed sheet 22 in the filling direction F serves to
inhibit
movement of the fitted bed sheet 22 relative to the mattress 24, limiting the
formation of
wrinkles, creases or other characteristics that cause irritation points.
FIG. 4 depicts another embodiment of the present invention. Elements
illustrated
in FIG. 1, which correspond, either identically or substantially, to the
elements described
above with respect to the embodiment illustrated by FIGS. 1 and 2, have been
designated by corresponding reference numerals increased by one hundred.
Unless
otherwise stated, the embodiment illustrated by FIG. 4 is constructed and
assembled in
the same basic manner as the embodiment illustrated by FIG. 4.
FIG. 4 illustrates a portion of a fabric material 110 constructed in
accordance with
another embodiment of the present invention. In an embodiment, the fabric
material
110 is woven in a plain weave construction. In an embodiment, FIG. 4
illustrates the
face-side of the material 110 which shows a repeating pattern of five (5)
strands of warp
yam 116 in a warp direction, as indicated by the arrows W, and a repeating
pattern of
five (5) strands of alternating filling yarn 118 and filling yarn 120 in a
filling or weft
direction, as indicated by arrows F. In an embodiment, the strands of the
filling yarn
116 provided in the warp W direction are made of filament rayon. In an
embodiment,
the strands of filling yarn 118 are made from a PLA polymer, nylon or a
polyester yarn
base that are inherently impregnated with silver ions, while the strands of
the filling yarn
120 are made from PLA polymer, nylon or polyester yarn base that are
inherently
impregnated with copper ions and are alternately inserted in the filling
direction F (i.e.,
the filling yarn 120 is inserted in one pick, alternating with the filling
yarn 118 in the next
pick, and so on). Alternatively, in another embodiment, polyester or nylon
yarn may be
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used as the base in the filling yarns 118, 120.
In an embodiment, the filling yarn 118 is fabricated from fibers that have
inherent
silver ions added to the base material of the master batch (e.g., PLA polymer,
nylon or
polyester yarn) of the fiber slurry in a process such as that which is
disclosed in the '411
International Publication. Upon extrusion of the fiber, the silver ions are
inherently part
of the fiber. Likewise, the filling yarn 120 may be fabricated from fibers
which have
inherent copper ions added to the base material (e.g., PLA polymer, nylon or
polyester
yarn) of the master batch of the fiber slurry in the process disclosed in the
'411
International Publication, Upon extrusion of the fiber, the copper ions are
inherently part
of the fiber.
In an embodiment, the fabric material 110 may be fabricated into pillow cases
for
covering, for example, the pillow 26 shown in FIG. 3, and a top sheet (not
shown) for
use with the fitted bed sheet fabric material 10 or 110. In an embodiment, the
plain
weave of the fabric material 110 provides the same coefficient of friction on
the face-
side and the back-side. In an embodiment, the silver and copper ions of the
filling yarns
118, 120 have antimicrobial and healing properties which are equivalent to
those
provided by the five-harness filling satin weave of the fabric material 10.
It should be appreciated that the present invention provides numerous
advantages over the prior art discussed above, For instance, the fitted bed
sheet 22
mitigates the formation of pressure ulcers and helps to heal existing pressure
ulcers.
More particularity, the fitted bed sheet 22 has a low coefficient of friction,
and has
antimicrobial agents that inhibit the development of micro-organisms, and has
healing
capabilities which are effective in reducing skin-born irritations. In an
embodiment, the
rayon used in the warp direction W possesses a low coefficient of friction and
has
significant absorption properties. In an embodiment, the absorption properties
wick-
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away moisture from the skin of the patient and contributes to the evaporation
of
moisture, which keeps the skin of the patient dry. This absorption prevents an
environment conducive to bacterial growth and wicks odor-causing moisture from
patients that are incontinent. In an embodiment, the rayon used in the warp
yarn 16 in
the warp direction W also has a natural cool feeling to the touch, This, in
addition to its
moisture wicking-action, assists in keeping the overall body temperature of
the patient
as cool as possible while resting or sleeping on the fitted bed sheet 22. The
fitted bed
sheet 22 is also breathable and disposable at the end of its useful life. For
instance, in
an embodiment, if the fitted bed sheet 22 is constructed with rayon in the
warp direction
W, and PLA polymer, nylon or polyester yarn infused with copper and silver
ions in the
filling direction F, the material is 100% biodegradable. In another
embodiment, if the
fitted bed sheet 22 is constructed with rayon in the warp direction W and
nylon or
polyester infused with copper and silver ions in the filling direction F, it
is compostable.
In an embodiment, silver ions, along with PLA polymer, nylon or polyester
yarn,
have antimicrobial properties which will inhibit the growth of bacteria on the
surface of
the fitted bed sheet 22 as well as on the skin of the patient, thereby
minimizing or
eliminating bacterial growth which is a contributing factor to the formation
of pressure
ulcers. Copper ions are known to be a healing agent. The combination of the
silver
ions and copper ions in the fitted bed sheet 22 provides both antimicrobial
and healing
properties. Because, upon extrusion of the fiber, the silver ions are
inherently part of
the fiber of the filling yarn 18, and the copper ions are part of the fiber of
the filling yarn
20 (i.e., not just applied to their exterior surface), the antimicrobial and
healing
properties provided by the silver and copper ions will not wear away as the
fitted bed
sheet 22 is used and laundered over its useful life.
It should be noted that the present invention can have numerous modifications
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and variations. For instance, in an embodiment, the weave construction of the
fabric
material 10 may be provided with a float in the filling direction F which is
less than 4
strands of warp yarn 16. In an embodiment, the number of strands of the
filling yarn 18
in the filling direction F may be greater or less than the number of strands
of the filling
yarn 20 in the filling direction F. In an embodiment, the strands in the
filling direction
may include only the filling yarn 18. In an embodiment, the strands in the
filling direction
F may include only the filling yarn 20. Examples of other weave construction
that may
be utilized in the fabric of the present invention (i.e., in addition to the 5-
harness filling
satin weave of the fabric material 10 and the plain weave of the material 110)
are twill
weaves and sateen weaves. In an embodiment, the fabric materials 10, 110 are
scoured to remove any spin finish, oils, or foreign matter. In other
embodiments, the
addition of other conditioning substances, such as wet processing using
cationic
softeners, may also be applied to the fabric materials 10,110. In an
embodiment, the
fabrics 10, 110 are dried in a tenter frame and calendared to make the fabric
materials
10, 110 feel smoother. In other embodiments, the fabric materials 10, 110 are
inspected and rolled for subsequent processing of cutting according to end
product
specifications or applicable device dimensions.
It will be understood that the embodiment described herein is merely exemplary
and that a person skilled in the art may make many variations and
modifications without
departing from the spirit and scope of the invention. For instance, all such
variations
and modifications, including those described hereinabove, are intended to be
included
within the scope of the invention and as defined in the appended claims.
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