Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
CA 02533761 2006-01-24
WO 2005/045111 PCT/US2004/033603
ENHANCED SURFACE GEOMETRY SHEETING
Background of the Invention
Field of the Invention
[0001] This invention is directed to woven fabric sheeting.
Description of Related Art
[0002] Woven fabric sheeting typically is made of 100% cotton or a
combination of cotton and a synthetic material such as, for example,
polyester.
Sheeting made entirely of cotton usually is quite comfortable to the touch.
However, such all-cotton sheeting tends to lack long-term durability. For
example, the sheeting may deteriorate at an undesirably fast rate due to yarn
damage from normal washing and use. In contrast, sheeting which includes a
synthetic material typically has a higher durability. However, this feature
comes at
the expense of comfort.
CA 02533761 2006-01-24
WO 2005/045111 PCT/US2004/033603
2
[0003] In an effort to combine comfort features of cotton fabrics with
durability advantages of synthetic fabrics, U.S. Patent No. 5,495,874 (owned
by
the assignee of the present invention) proposes a plain woven fabric sheeting
constructed of cotton warp yarns and polyester filament filling yarns.
However, it
would be desirable to make that plain weave fabric more comfortable.
[0004] Thus, further improvements in woven fabric sheeting are desired.
Summary of the Invention
[0005] I have determined that a woven sheeting construction which
includes warp yarn floats and a synthetic filament yarn in the filling is
sufficient to
provide a woven fabric sheeting with improved levels of comfort and
durability.
Such a construction brings a greater proportion of each of the floated yarns
(i.e.,
the warp yarns) to the surface of the sheeting, which tends to increase
surface
tactile comfort. Thus, the floated yarns may be said to be "comfort yarns". At
the
same time, the synthetic filament yarn enhances the durability of the
sheeting. In
addition, the construction provides differentially elevated and/or depressed
areas
or designs on the surface of the sheeting, which may create pathways or
channels
for increased airflow through and/or across the sheeting. This feature not
only
enhances comfort, but also is believed to have a positive impact on skin care.
[0006] Alternatively, the sheeting may include filling yarn floats and a
synthetic filament yarn in the warp. And if desired, the sheeting may include
both
warp yarn floats and filling yarn floats, with the filling and/or the warp
including a
synthetic filament yarn. These constructions also achieve the advantages
described above.
CA 02533761 2006-01-24
WO 2005/045111 PCT/US2004/033603
3
[0007] The woven fabric sheeting may be characterized by a float pattern,
x/y, which is specific to a given warp or filling yarn (and/or to a plurality
of warp
or filling yarns) as that yarn relates to yarns in the perpendicular direction
of the
weave. x represents the number of adjacent yarns (at least two) over which a
floated yarn extends or "floats", and y represents the number of adjacent
yarns (at
least one) under which the floated yarn passes. Although not required, a float
pattern typically is repeated along the length of a given warp yarn or filling
yarn.
The portion of the floated yarn which extends over two or more adjacent yarns
is
referred to as a "float". In general, each of x and y is a whole number
greater
than zero (0), and x is at least two (2). If a warp or filling yarn does not
include
floats, then that yarn does not have a float pattern.
[0008] Any of the floated yarns may be formed of natural fibers, synthetic
staple fibers, and/or synthetic filaments. Advantageously, the floated yarns
are
natural yarns, for example, cotton yarns to provide the most desired comfort.
At
least one of the yarns which is perpendicular (in the weave) to a given
floated
yarn is formed of synthetic filament, for example, polyester. Advantageously,
a
plurality of the perpendicular yarns in the sheeting are formed of synthetic
filament. If desired, one or more of the perpendicular yarns may be formed of
natural fibers and/or synthetic staple fibers.
[0009] The woven fabric sheeting may be constructed using any non-
plain weave pattern or combination of such patterns. For example, the sheeting
may be formed using a twill weave, a satin weave, a gabardine weave, a
herringbone weave, or a combination of such weaves. In addition, any suitable
CA 02533761 2006-01-24
WO 2005/045111 PCT/US2004/033603
4
yarn float pattern may be used. Nonlimiting examples include a 2/1 twill weave
pattern, a 2/2 twill weave pattern, and a 4/1 satin weave pattern, although
other
float patterns and weaves with floated yarns are possible, as will be
appreciated
by one of ordinary skill in the art.
[0010] By virtue of the foregoing, there is thus provided a woven fabric
sheeting having advantages over prior woven fabric sheetings. These and other
advantages of the present invention shall be made apparent from the
accompanying drawings and description of the drawings.
Brief Description of the Drawings
[0011] The accompanying drawings, which are incorporated in, and
constitute a part of this specification, illustrate versions of the invention,
and,
together with the general description of the invention given above, and the
detailed description of versions of the invention given below, serve to
explain the
principles of the invention.
[0012] Fig. 1 is a perspective view of a woven fabric sheeting in
accordance with the principles of the invention;
[0013] Fig. 2 is an enlarged, fragmentary top view, not to scale, of a
portion of a woven fabric sheeting in accordance with the principles of the
invention; and
[0014] Fig. 3 is an enlarged, fragmentary top view, not to scale, of a
portion of another woven fabric sheeting in accordance with the principles of
the
present invention.
CA 02533761 2006-01-24
WO 2005/045111 PCT/US2004/033603
Detailed Description of the Drawings
[0015] With reference to Fig. 1, a woven fabric sheeting 10 includes a first
surface 12 and an oppositely-disposed second surface 14, with the surfaces 12,
14
extending between a left selvage 16 and a right selvage 18, as well as a top
or
trailing end 20 and a bottom or leading end 22.
[0016] With reference to Fig. 2, a woven fabric sheeting 30 includes a
plurality of warp yarns 32 and filling yarns 34, with the yarns 32, 34 woven
together in a twill weave having a warp yarn float pattern of 2/1. In other
words,
a series of floats, as at 36a,b,c,d, are staggered in the filling direction,
with the
floats being formed by the warp yarns 32. As seen in Fig. 2, the 2/1 float
pattern
simply indicates that each of the warp yarns 32 extends, or "floats", over two
adjacent filling yarns, and then passes under a single filling yarn, a pattern
which
is repeated along the length of each of the warp yarns 32. The warp yarns 32
are
natural yarns, for example, cotton yarns; and the filling yarns 34 are
multifilament
yarns, for example polyester multifilament yarns. Because the warp yarns 32
are
floated, a greater proportion of each of the warp yarns 32 is present at the
first
surface 12 of the sheeting 30. In contrast, the filament filling yarns 34 are
not
floated, and therefore a lesser proportion of each of these yarns 34 is
present at
the surface 12. The net effect is an increase in tactile comfort at the
surface 12
and an overall enhancement in durability.
[0017] With reference to Fig. 3, a woven fabric sheeting 40 includes a
plurality of warp yarns 42 and a plurality of filling yarns 44, with the yarns
42, 44
woven together in a twill weave which includes a plurality of filling yarn
floats, as
CA 02533761 2006-01-24
WO 2005/045111 PCT/US2004/033603
6
at 46a,b,c,d, having a float pattern of 2/1. In this particular sheeting 40,
the filling
yarn floats are staggered in the warp direction. In addition, given the 2/1
float
pattern, each of the filling yarns 44 extends (i.e., "floats") over two
adjacent warp
yarns, and under a single warp yarn, with this pattern being repeated along
the
length of each of the filling yarns 44. The warp yarns 42 are multifilament
yarns,
for example, polyester multifilament yarns; and the filling yarns 44 are
natural
yarns, for example cotton yarns. Because the filling yarns 44 are floated, a
greater proportion of each of the yarns 44 is present at the first surface 12
of the
sheeting 40. In contrast, the filament warp yarns 42 are not floated, and
therefore
a lesser proportion of each of these yarns 42 is present at the surface 12.
The
result is an increase in tactile comfort at the surface 12 and an overall
enhancement in durability.
[0018] Each of the woven fabric sheetings described above provides
several benefits and advantages. For example, the sheeting offers an enhanced
level of comfort and durability. In addition, air is able to pass across or
through
the sheeting to an extent which not only improves comfort, but also may have a
favorable impact on skin care.
[0019] In use, the woven fabric sheeting may be formed into suitable
items. For example, any of the sheetings may be formed into sheets, pillow
cases,
and the like, all of which are both comfortable and durable.
[0020] By virtue of the foregoing, there is thus provided a woven fabric
sheeting having advantages over prior woven fabric sheetings.
CA 02533761 2006-01-24
WO 2005/045111 PCT/US2004/033603
7
[0021] While the present invention has been illustrated by the description
of versions and specific examples, and while the versions have been described
in
considerable detail, I do not intend to restrict or in any way limit the scope
of the
appended claims to such detail. Additional advantages and modifications
readily
will appear to those skilled in the art. For example, although the drawings
illustrate a twill weave, any non-plain weave may be used, with nonlimiting
examples including a twill weave, a satin weave, a gabardine weave, a
herringbone weave, and combinations of such weaves. And although
multifilament yarns are used in the sheeting versions illustrated in Figs. 2
and 3, a
woven fabric sheeting may use monofilament yarns - either in place of, or in
combination with, multifilament yarns. In addition, while Figs. 2 and 3 depict
sheetings having a single float pattern which is maintained throughout the
sheeting, as well as floats in only one of the weave (i.e., warp or filling)
directions,
any suitable float pattern or combination of float patterns may be used -
either in
a single weave (i.e., warp or filling) direction or in both (i.e., both warp
and filling)
weave directions. The invention, in its broader aspects, therefore is not
limited to
the specific details, representative apparatus and methods, and illustrative
examples shown and described. Accordingly, departures may be made from such
details without departing from the scope or spirit of my general inventive
concept.
[0022] Having described the invention, I claim:
