U.S. patent application number 12/784772 was filed with the patent office on 2011-10-06 for coverlet and method of producing a coverlet.
This patent application is currently assigned to VALLEY FORGE FABRICS, INC.. Invention is credited to J. Michael Dobin.
Application Number | 20110239369 12/784772 |
Document ID | / |
Family ID | 44707897 |
Filed Date | 2011-10-06 |
United States Patent
Application |
20110239369 |
Kind Code |
A1 |
Dobin; J. Michael |
October 6, 2011 |
Coverlet and Method of Producing a Coverlet
Abstract
A coverlet includes a first back layer having edges, a second
middle layer having edges and a batting layer having edges and
being disposed between and quilted to the first and second layers,
A third face layer has edges, covers the second layer and is
stitched to the first and second layers and to the batting layer. A
binding, preferably between 1/2 and 1 inch in width, covers all of
the edges. The first, second and third layers are all formed of the
same fabric, especially a lyocell blend. The batting layer is
preferably a lyocell blend and in particular a blend with
polyester. A method of producing the coverlet is also provided.
Inventors: |
Dobin; J. Michael; (Pompano
Beach, FL) |
Assignee: |
VALLEY FORGE FABRICS, INC.
Pompano Beach
FL
|
Family ID: |
44707897 |
Appl. No.: |
12/784772 |
Filed: |
May 21, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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61320359 |
Apr 2, 2010 |
|
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Current U.S.
Class: |
5/502 ;
112/475.01 |
Current CPC
Class: |
A47G 9/0207 20130101;
D05B 11/00 20130101 |
Class at
Publication: |
5/502 ;
112/475.01 |
International
Class: |
A47G 9/02 20060101
A47G009/02; D05B 1/00 20060101 D05B001/00 |
Claims
1. A coverlet, comprising: a first back layer having edges, a
second middle layer having edges and a batting layer having edges
and being disposed between and quilted to said first and second
layers; a third face layer having edges, covering said second layer
and being stitched to said first and second layers and to said
batting layer; and a binding covering all of said edges; said
first, second and third layers all being formed of the same
fabric.
2. The coverlet according to claim 1, wherein said first, second
and third layers are all formed of a lyocell blend fabric.
3. The coverlet according to claim 1, wherein said binding is
approximately 21/2 inches wide and is folded back on itself leaving
a width of approximately 1/2 inch above said first layer and below
said third layer and is stitched to said first, second and third
layers and to said batting layer.
4. The coverlet according to claim 1, wherein said binding has a
width of approximately 1/2 to 1 inch above said first layer and
below said third layer and is stitched to said first, second and
third layers and to said batting layer.
5. The coverlet according to claim 1, wherein said batting layer is
a lyocell blend.
6. The coverlet according to claim 1, wherein said batting layer is
a lyocell and polyester blend.
7. The coverlet according to claim 6, wherein said batting layer
weighs from 2 to 8 ounces per square yard.
8. The coverlet according to claim 1, which further comprises edge
stitching disposed all along said edges of said first, second and
third layers, said batting layer and said binding.
9. The coverlet according to claim 8, wherein said edge stitching
has between 8 and 12 stitches to the inch.
10. The coverlet according to claim 1, wherein said binding is
stitched to said first, second and third layers and to said batting
layer with between 10 and 15 stitches to the inch.
11. A method of producing a coverlet, the method comprising the
following steps: providing a first back layer, a second middle
layer and a third face layer of the same fabric having edges;
placing a batting layer having edges between the first and second
layers; quilting the first layer, the second layer and the batting
layer together; covering the second layer with the third layer;
stitching the third layer to the first and second layers and to the
batting layer; and covering all of the edges with a binding.
12. The method according to claim 11, which further comprises
providing all of the first, second and third layers as a lyocell
blend fabric.
13. The method according to claim 11, which further comprises
providing the binding with a width of approximately 21/2 inches,
folding the binding back on itself leaving a width of approximately
1/2 inch above the first layer and below the third layer, and
stitching the binding to the first, second and third layers and to
the batting layer.
14. The method according to claim 11, which further comprises
providing the binding with a width of approximately 1/2 to 1 inch
above the first layer and below the third layer, and stitching the
binding to the first, second and third layers and to the batting
layer.
15. The method according to claim 11, which further comprises
providing the batting layer as a lyocell blend.
16. The method according to claim 11, which further comprises
providing the batting layer as a lyocell and polyester blend.
17. The method according to claim 16, wherein the batting layer
weighs from 2 to 8 ounces per square yard.
18. The method according to claim 11, which further comprises
placing edge stitching all along the edges of the first, second and
third layers, the batting layer and the binding.
19. The method according to claim 18, which further comprises
providing the edge stitching with between 8 and 12 stitches to the
inch.
20. The method according to claim 11, which further comprises
stitching the binding to the first, second and third layers and to
the batting layer with between 10 and 15 stitches to the inch.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the priority under 35 U.S.C. 119(e)
of U.S. Provisional Patent Application No. 61/320,359, filed Apr.
2, 2010.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to a unique type of coverlet and
method of producing a coverlet, which maintain the properties of a
coverlet, but have the luxury appearance of a duvet.
[0004] 2. Description of the Related Art
[0005] U.S. Pat. No. 7,150,055 discloses a multi-layered bedclothes
material in which four layers, including a cotton sheeting, a poly
or polycotton sheeting, a polyester or polyester acrylic fill and a
cotton or polycotton cloth fabric, are shown in FIG. 7 and quilting
is shown in FIG. 8 thereof.
[0006] U.S. Pat. Nos. 5,925,581 and 5,806,154 respectively disclose
a textile laminate and a method of making a textile laminate, in
which a quilted fabric 37 shown in FIG. 6 is made up of several
layers, including an outer layer of quilt, a face layer, second
fibers of polypropylene, a fiber fill web substrate and an outer
layer of quilt, are shown in FIG. 5.
[0007] U.S. Pat. No. 3,801,420 shows a plastic quilted bedspread
having a sandwich of a top vinyl layer, a padding layer of Dacron
or urethane foam and a third interfacing layer, as well as a bottom
layer of nylon, with a binding or beading at the edges. The binding
or beading at the edges has a simple C-shaped cross-section.
[0008] The prior art products described above use different
materials for the layers thereof in order to use less expensive
fabrics in regions not seen by the user as well as single-rolled
bindings. However, that leads to different shrinkages upon washing
and drying, thus degrading long-term performance, especially when
washed and dried for industrial uses. They also do not provide a
binding which is double-rolled or folded back on itself.
BRIEF SUMMARY OF THE INVENTION
[0009] It is accordingly an object of the invention to provide a
coverlet and a method of producing a coverlet, which overcome the
hereinafore-mentioned disadvantages of the heretofore-known
products and methods of this general type and in which the coverlet
has a durability and life span suitable for institutional uses, a
binding which is double-rolled or folded back on itself and a
lyocell blend batting.
[0010] With the foregoing and other objects in view there is
provided, in accordance with the invention, a coverlet, comprising
a first back layer having edges, a second middle layer having edges
and a batting layer having edges and being disposed between and
quilted to the first and second layers. A third face layer has
edges, covers the second layer and is stitched to the first and
second layers and to the batting layer. A binding covers all of the
edges. The first, second and third layers are all formed of the
same fabric.
[0011] With the objects of the invention in view, there is also
provided a method of producing a coverlet. The method comprises
providing a first back layer, a second middle layer and a third
face layer of the same fabric having edges. A batting layer having
edges is placed between the first and second layers. The first
layer, the second layer and the batting layer are quilted together.
The second layer is covered with the third layer. The third layer
is stitched to the first and second layers and to the batting
layer. All of the edges are covered with a binding.
[0012] The coverlet produced according to the invention has a
durability and life span suitable for institutional uses.
[0013] In accordance with another feature of the invention, the
first, second and third layers are all formed of a lyocell blend
fabric. This permits the layers of the invention to not only have
the advantages of lyocell, but to shrink equally when washed and
dried, even under harsh industrial use conditions.
[0014] In accordance with a further feature of the invention, the
binding is approximately 21/2 inches wide and is folded back on
itself or double-rolled leaving a width of approximately 1/2 inch
above the first layer and below the third layer and is stitched to
the first, second and third layers and to the batting layer. The
binding may have a width of approximately 1/2 to 1 inch above the
first layer and below the third layer and be stitched to the first,
second and third layers and to the batting layer. A binding of this
width has never before been possible when using a lyocell blend
binding or a 100% lyocell binding, because of the difficulty of
working with such a fabric.
[0015] In accordance with an added feature of the invention, the
batting layer is a lyocell blend, such as polyester and lyocell,
and may weigh from 2 to 8 ounces per square yard. Lyocell provides
particular advantages as a batting, especially as a blend with
polyester, as will be explained below.
[0016] In accordance with an additional feature of the invention,
edge stitching is disposed all along the edges of the first, second
and third layers, the batting layer and the binding. The edge
stitching may have between 8 and 12 stitches to the inch. Thus, the
third layer is held in place by the edge stitching and not by
quilting.
[0017] In accordance with a concomitant feature of the invention,
the binding is stitched to the first, second and third layers and
to the batting layer with between 10 and 15 stitches to the
inch.
[0018] Thus, the coverlet according to the invention is formed of
three layers of fabric and a batting or filling that is quilted,
stitched and attached with a binding on all four sides.
[0019] Traditional coverlets include two fabrics and a batting that
are quilted and stitched together. There is no binding and no third
layer of fabric.
[0020] The process steps for making the coverlet according to the
invention can be roughly divided into two separate process
streams:
The process stream for creating the fiber fill used to stuff the
coverlet according to the invention. The process stream for the
assembly of the coverlet according to the invention, which
includes: Cutting and sewing of the fabric to create a shell.
Filling the shell with the afore-mentioned fiber fill. Quilting the
filled shell to hold the fiber in place in the final product.
Closing and finishing the product to create the completed coverlet
according to the invention. Packing and shipping the coverlet
according to the invention.
[0021] The diagram of the process shown in FIG. 5 is used to create
fiber fill for the coverlet according to the invention.
[0022] This process mixes precise percentages of a variety of
staple polyester, recycled polyester fiber and lyocell fibers along
with low-melt binder fibers.
[0023] This fiber mix goes through a series of hoppers, blenders
and openers in order to open up and thoroughly mix the various
fiber types so they are evenly distributed into a fiber blend.
[0024] At that point, the loose fiber blend goes into the garneting
machine, first through a card hopper, then a shaker shoot, then a
feed table and finally through the garneting card itself which
substantially combs and aligns the fiber creating a web. This web
is then double-lapped to create a double web.
[0025] This double web is further lapped to create a batting which
is conveyed through an oven with temperature and dwell-time
precisely set to allow the inder fibers to melt into the other
fibers and form a roll of cohesive fiber fill that balances
structural integrity and softness.
[0026] When the roll reaches a maximum workable diameter,
corresponding to a length of between 40 to 60 yards, the fiber fill
is cut by using a non-heated blade. The use of a non-heated blade
as opposed to a hot-wire is required due to the combustible nature
of the cellulosic fiber used in this particular blend.
[0027] Other features which are considered as characteristic for
the invention are set forth in the appended claims.
[0028] Although the invention is illustrated and described herein
as embodied in a coverlet and a method of producing a coverlet, it
is nevertheless not intended to be limited to the details shown,
since various modifications and structural changes may be made
therein without departing from the spirit of the invention and
within the scope and range of equivalents of the claims.
[0029] The construction of the invention, however, together with
additional objects and advantages thereof will be best understood
from the following description of the specific embodiment when read
in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0030] FIG. 1 is a diagrammatic, bottom-plan view of a coverlet
according to the invention showing a first layer of quilted
fabric;
[0031] FIG. 2 is a top-plan view of a coverlet according to the
invention showing a third layer or face fabric;
[0032] FIG. 3 is a fragmentary, enlarged, cross-sectional view of
the coverlet according to the invention, which is taken along a
line 3-3 of FIG. 1, in the direction of the arrows and shows all of
the layers thereof;
[0033] FIG. 4 is a fragmentary, perspective view of a corner of the
coverlet according to the invention showing all of the layers
thereof; and
[0034] FIG. 5 is a diagram showing the process used to create fiber
fill for the coverlet according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0035] Referring now to the figures of the drawing in detail and
first, particularly, to FIGS. 1 and 2 thereof, there is seen a
first layer of fabric 1 forming a bottom of the coverlet and a
third layer of fabric 3 forming a top of the coverlet, according to
the invention.
[0036] In order to assemble the coverlet, fabric is supplied on
non-illustrated rolls that are generally between 90 and 120 inches
wide and between 100 and 300 yards long. The coverlet according to
the invention is made in the following order. A first layer of
fabric 1 is placed on a non-illustrated quilting machine. This
layer 1 is known as a "back fabric" as it will be the back of the
finished coverlet according to the invention. A batting 10 shown in
FIG. 3 is placed on the back fabric 1. A second layer of fabric 2
is placed on the batting 10, effectively making a sandwich of the
batting 10 between the two fabrics 1, 2. This second layer 2 is
referred to as a "middle fabric" as it will be the middle of the
finished coverlet according to the invention. It is noted that the
two fabrics 1, 2 and the batting 10 are cut evenly so they are all
the same size. The two fabrics 1, 2 are quilted along stitching 11
with the batting 10 between them. They are quilted fully to the
edges of the fabrics 1, 2.
[0037] Once the quilting is complete, the quilted piece 1, 2, 10
(it is now considered a single piece) is moved to a table where a
third layer of fabric 3 is placed on top of the piece 1, 2, 10.
This third fabric 3 is referred to as a "face fabric" as it will
end up being the face of the coverlet according to the invention.
It is noted that this third layer 3 is the same size as the quilted
piece 1, 2, 10 it is laying on. The third layer ("face fabric") is
stitched at a sewing station to the quilted piece by edge stitching
12. It is stitched on all 4 sides using between 8 and 12 stitches
per inch. The three layers of fabric 1, 2, 3 and the batting 10 are
now considered one piece.
[0038] The edges of the three layers 1, 12, 3 are sewn together
using a special 1/2 inch binding 15. A 21/2 inch strip of the face
fabric is bias cut (a diagonal cut of fabric that allows the
binding to smoothly be sewn around the rounded edges with limited
puckering) to form the binding 15. Lengthwise edges 16 of the
binding 15 are rolled inside itself so that no raw edges are
exposed in order to prevent fraying. A 1/2 inch of the binding 15
remains on top and on the bottom of the coverlet according to the
invention.
[0039] FIG. 4 shows a corner of the coverlet according to the
invention, in which the first, second and third layers 1, 2, 3 as
well as the batting layer 10 are shown. The quilted stitching 11 is
also shown, but the edge stitching 12 has been omitted to show the
layers in a partially separated condition.
[0040] A final inspection is performed, any lint or debris found is
blown off with a pneumatic hose, spots are cleaned off and second
quality units are segregated into a separate area. Each unit is
packed in polyurethane bag and a size label is affixed to the back
of bag in a lower right hand corner. Then four to six units are
packed into a carton and each carton is properly labeled with a
carton and a case label, assembled into an order and shipped.
[0041] One unique aspect of the coverlet according to the invention
is that all three fabrics 1, 2, 3 being used are of the same
construction and content. Although the "middle fabric" 2 is not in
plain view and an inexpensive substitute would therefore provide
substantial savings, the coverlet according to the invention does
not follow that less expensive course. That is because hotels and
institutional uses have strict washing and drying requirements.
Industrial washing machines are used, and those are neither gentle
nor easy on a product during the laundering process. Using a
"middle fabric" 2 that is the same content and construction gives
strength to the product.
[0042] Fabrics also shrink in machine washing and drying. Having
"the middle" fabric 2 shrink at the same exact rate as the face
fabric 3 and the back fabric 1 is vital to ensure longterm
performance, and this can only be possible with having the same
construction and content for all three layers of fabric 1, 2,
3.
[0043] The fabrics that form the coverlet according to the
invention are made up of various textiles that include but are not
limited to:
100% Cotton
100% Polyester
[0044] 100% recycled polyester Polyester and cotton blend Cotton
and Lyocell blend Polyester and lyocell blend Cotton, polyester,
and lyocell blend
[0045] Lyocell is a generic fiber name and is defined by the FTC
as:
A cellulose fiber obtained by an organic solvent spinning process
where: 1)"Organic solvent" means a mixture of organic chemicals and
water, and 2)"solvent spinning" means dissolving and spinning
without the formation of a derivative.
[0046] The batting 10 that is inside of the coverlet according to
the invention ranges from 2 ounces to 8 ounces per square yard.
[0047] A second unique aspect of the coverlet according to the
invention is that the batting 10 is a blend of lyocell and
polyester fibers. There are no three-layer products existing with a
lyocell blend batting. The batting contents range from, but are not
limited to:
100% polyester 100% recycled polyester 30% lyocell fiber and 70%
polyester 30% lyocell fiber and 70% recycled polyester A range of
20%-50% lyocell mixed with 50%-80% polyester or recycled
polyester
[0048] The third and most unique aspect of the coverlet according
to the invention is the 1/2 inch binding 15 that is on all four
sides. Creating and executing a 1/2 inch binding is difficult as
there is very little fabric making up the binding and holding the
product together. The binding 15 must be double rolled and stitched
with a minimum of 10 stitches per inch. The binding 15 can range in
size from 1/2 inch to 1 inch and the stitches can range from 10 to
15 per inch.
[0049] The corporate assignee of the instant application, Valley
Forge Fabrics, is producing coverlets according to the invention
for multiple sales avenues including, but not limited to, hotel
beds, institutional beds, and residential beds. Valley Forge
Fabrics is using various constructions, designs, colors and
patterns on the coverlets according to the invention.
[0050] Valley Forge Fabrics supplies bedding products to the
hospitality and lodging industry and there are certain requirements
of the coverlet according to the invention apart from technical
testing:
The batting cannot clump after continuous launderings. The batting
cannot shift in laundering and use. The face and back fabrics must
keep a well kept appearance. The weight of the batting must be
consistent throughout the coverlet. The weight of the batting must
be consistent from coverlet to coverlet on separate orders.
[0051] There are certain ASTM requirements that bedding in hotels,
lodging, and institutions is required to meet:
ASTM D4034 Seam Slippage Test--ACT standards call for a minimum of
25 pounds in warp and weft, Valley Forge Fabrics has a self-imposed
minimum of 35 pounds in warp and weft for this test. ASTM D2261
Tongue Tear Test--Minimum of 8 pounds. ASTM D5034 Tensile
Strength/Breaking strength test--Minimum 35 pounds. FR code of
California bulletin 117 must be met or exceeded. ASTM D5362 Bean
Bag Snag test must be met or exceeded. AATCC 8 Wet/Dry
Crocking--The product must meet or exceed a 4.0 for dry and a 3.5
rating for wet crocking. ASTM D3512 Random Tumble Pill
test--Fabrics on a coverlet according to the invention must meet or
exceed a rating of 4.0. AATCC 96-2004 Dimensional Changes in
laundering--Products must have less than 3% shrinking after 3
launderings.
* * * * *