U.S. patent application number 17/458235 was filed with the patent office on 2022-03-03 for light woven sheet.
The applicant listed for this patent is Casper Sleep Inc.. Invention is credited to Rebecca Caroline Cockerham.
Application Number | 20220064825 17/458235 |
Document ID | / |
Family ID | |
Filed Date | 2022-03-03 |
United States Patent
Application |
20220064825 |
Kind Code |
A1 |
Cockerham; Rebecca
Caroline |
March 3, 2022 |
LIGHT WOVEN SHEET
Abstract
A woven sheet that is lightweight and breathable, while also
being a durable, long-lasting type. The lightweight woven sheet
comprises a dynamic grid construction that allows moisture vapor to
escape while preserving durability of the sheet. The sheet includes
a first section including a first type of weave having a first grid
pattern and a second section including a second type of grid having
a second grid pattern. The first weave is an open-weave, which
makes the sheet breathable and lowers the overall weight of the
sheet, while the second weave is a plain weave that provides
durability to the overall sheet.
Inventors: |
Cockerham; Rebecca Caroline;
(Wilmington, NC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Casper Sleep Inc. |
New York |
NY |
US |
|
|
Appl. No.: |
17/458235 |
Filed: |
August 26, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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63073413 |
Sep 1, 2020 |
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International
Class: |
D03D 15/217 20060101
D03D015/217; D03D 3/00 20060101 D03D003/00; D03D 11/00 20060101
D03D011/00 |
Claims
1. A woven sheet comprising, a first section comprising a first
weave having a first grid pattern; and a second section comprising
a second weave having a second grid pattern, the second section is
coupled to the first section; wherein an area of first section is
greater than an area of the second section; wherein the first grid
pattern is less dense than the second grid pattern; wherein the
first weave contributes most to an air permeability characteristic
of the woven sheet; and wherein the second weave contributes most
to a durability characteristic of the woven sheet.
2. The woven sheet of claim 1, wherein the second weave is a plain
weave.
3. The woven sheet of claim 2, wherein the second grid pattern is a
1-by-1 grid pattern.
4. The woven sheet of claim 1, wherein the first weave is a dobby
weave.
5. The woven sheet of claim 4, wherein the first pattern is a
2-by-2 grid pattern.
6. The woven sheet of claim 1, wherein the air permeability
characteristic of the first section is about 304 cubic feet per
minute or greater.
7. The woven sheet of claim 1, wherein a weight characteristic of
the woven sheet is about 85 grams per square meter or less.
8. The woven sheet of claim 1, wherein the first section comprises
a first geometric pattern and a second geometric pattern.
9. The woven sheet of claim 1, wherein the first section and the
second section are directly connected.
10. The woven sheet of claim 1, wherein the first section and the
second section comprise a lyocell fiber.
11. A woven sheet comprising: a first section having a 2-by-2 dobby
weave; and a second section having a 1-by-1 plain weave, the first
section contacting the second section, wherein an area of first
section is greater than an area of the second section; and wherein
the first section and the second section both comprise a lyocell
fiber.
12. A method of making a woven sheet, the method comprising the
steps of: weaving a first section using a first weave having a
first grid pattern; and weaving a second section using a second
weave having a second grid pattern, the second section coupled to
the first section; wherein an area of first section is greater than
an area of the second section; wherein the first grid pattern is
less dense than the second grid pattern; wherein the first weave
contributes most to an air permeability characteristic of the woven
sheet; and wherein the second weave contributes most to a
durability characteristic of the woven sheet.
13. The method of claim 12, wherein the second weave is a plain
weave.
14. The method of claim 13, wherein the second grid pattern is a
1-by-1 grid pattern.
15. The method of claim 12, wherein the first weave is a dobby
weave.
16. The method of claim 15, wherein the first pattern is a 2-by-2
grid pattern.
17. The method of claim 12, wherein the air permeability
characteristic is equal or greater than about 304 cubic feet per
minute.
18. The method of claim 12, wherein a weight characteristic of the
woven sheet is equal or less than about 85 grams per square
meter.
19. The method of claim 12, wherein the first section comprises a
first geometric pattern and a second geometric pattern.
20. The method of claim 12, wherein the first section and the
second section are connected directly.
21. The method of claim 12, wherein the first section and the
second section comprise a lyocell fiber.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional
Application No. 63/073,413 filed on Sep. 1, 2020. The above
identified patent application is herein incorporated by reference
in its entirety and no part of the application has been
disclaimed.
TECHNICAL FIELD
[0002] The present disclosure relates generally to the field of
woven fabrics, and the products made therefrom.
BACKGROUND
[0003] Heat retention in the bedding environment is a crucial topic
in the bedding and mattress industries, especially with the growth
of the foam mattress sector. While this issue has been studied in
depth for mattresses, innovations in sheeting and bedding
construction has been limited. Yet thermal regulation during sleep
is vital to getting a good night's rest, as temperature is one of
the main reasons for waking up during the night. Many products that
are designed to maintain body temperature only focus on fiber type,
while the construction of the fabric itself is fairly conventional.
Fiber type can influence cooling, but if the construction is not
open and breathable, the fabric will trap heat no matter what
fiber.
[0004] A few brands have marketed cooling sheets but have not
achieved cooling through weight and construction of the fabric.
Instead, these brands typically approach improvements from a fiber
blend perspective. For example, one brand claims cooling through
the use of synthetic fibers. This is a debatable approach since
synthetic fibers may feel cool to the first touch but will actually
warm up to body temperature over time.
[0005] Moreover, the allure of so-called "high quality" resulting
from high thread count sheeting may actually have a negative effect
on temperature. While high thread count may create a more durable
sheet, the higher thread count packs in more threads per inch of
fabric, creating less breathability and a hotter sleeping
sheet.
[0006] Prior art from other industries, such as the outdoor or
activewear apparel industry, may be analogous to this
density-focused textile technology. Most brands approach cooling
from a fiber choice perspective, but do not address construction of
the sheet itself.
SUMMARY
[0007] The objective is to provide a woven sheet that is
lightweight and breathable, while also being a durable,
long-lasting type. A bedsheet made of this type of lightweight
woven fabric comprises a dynamic (varying) grid construction that
allows moisture vapor to escape the bedding environment and keep
the sleeper comfortable and asleep throughout the night while
preserving durability of the fabric. The bedsheet made out of the
lightweight woven fabric described herein approaches cooling
holistically from both fiber type and construction
perspectives.
[0008] For example, a combination of light weight, low thread
count, and high tear strength in a dynamic dobby grid construction
provides a very breathable, soft, and durable sheet--optimal for
temperature regulation during sleeping. Other brands use typical
Percale or Sateen constructions and generally have not approached
fabrics in this weight class, typically due to durability. This
resulting product is actually more durable than other sheeting due
to the dynamic grid construction. The sheet made out of the
lightweight woven fabric of the present invention may be branded as
a HYPERLIGHT.TM. sheet.
[0009] The invented lightweight woven sheet can be successfully
used for many other bedding items, such as pillowcases, duvet
covers, mattress toppers, etc.
[0010] The invented woven sheet comprises a first section having a
2-by-2 dobby weave and a second section having a 1-by-1 plain
weave, the first section contacting the second section, wherein an
area of first section is greater than an area of the second
section; and wherein the first section and the second section both
comprise a lyocell fiber.
[0011] The invented woven sheet comprises a first section including
a first weave having a first grid pattern, and a second section
including a second weave having a second grid pattern. The second
section is coupled to the first section, wherein an area of first
section is greater than an area of the second section, and wherein
the first grid pattern is less dense than the second grid pattern.
The first weave contributes most to an air permeability
characteristic of the woven sheet, and the second weave contributes
most to a durability characteristic of the woven sheet. The second
weave can be a plain weave having, and second grid pattern can be a
1-by-1 grid pattern. The first weave can be a dobby weave, and the
first grid pattern can be a 2-by-2 grid pattern. The air
permeability characteristic of the first section can be about 304
cubic feet per minute or greater. The weight characteristic of the
woven sheet cane be about 85 grams per square meter or less. The
first section may comprise a plurality of geometric patterns, such
as a first geometric pattern and a second geometric pattern. The
first and second sections may be directly connected, and both may
comprise a lyocell fiber. The woven sheet may use the same yarn in
both warp and weft directions, or it may use different yarns.
[0012] The invention includes a method for making a woven sheet
comprising the steps of (i) weaving a first section using a first
weave having a first grid pattern and (ii) and weaving a second
section using a second weave having a second grid pattern, the
second section coupled to the first section, wherein the first
section has a greater area then the second section, the first grid
pattern is more open than the second grid pattern, such that the
first weave contributes most to air permeability of the woven
sheet, while the second weave contributes to durability of the
sheet.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The illustrated embodiments of the subject matter will be
best understood by reference to the drawings, wherein like parts
are designated by like numerals throughout. The following
description is intended only by way of example, and simply
illustrates certain selected embodiments of devices, systems, and
processes that are consistent with the subject matter as claimed
herein.
[0014] FIG. 1 shows a lightweight, breathable woven sheet in
accordance with an embodiment of the invention;
[0015] FIG. 2 shows a lightweight, breathable woven sheet in
accordance with another embodiment of the invention;
[0016] FIG. 3 is a more detailed view of a portion the lightweight,
breathable woven sheet in FIG. 2.
[0017] FIG. 4 is a set of test results showing certain properties
of a lightweight, breathable woven sheet in accordance with an
embodiment of the invention;
[0018] FIG. 5 is a set of test results showing certain other
properties of a lightweight, breathable woven sheet in accordance
with an embodiment of the invention;
[0019] FIG. 6 is a set of test results showing certain additional
properties of a lightweight, breathable woven sheet in accordance
with an embodiment of the invention;
DETAILED DESCRIPTION
[0020] The present invention provides a woven sheet that is
lightweight and breathable, while also being a durable,
long-lasting type. The lightweight woven sheet of the present
invention may use yarn made out of lyocell fiber, which is a type
of rayon fiber. The US Federal Trade Commission's regulations state
that rayon is "a manufactured fiber composed of regenerated
cellulose, as well as manufactured fibers composed of regenerated
cellulose in which substituents have replaced not more than 15% of
the hydrogens of the hydroxyl groups." The regulation further
states that "[w]here the fiber is composed of cellulose
precipitated from an organic solution in which no substitution of
the hydroxyl groups takes place and no chemical intermediates are
formed, the term lyocell may be used as a generic description of
the fiber." 16 CFR .sctn. 303.7(d) (2020).
[0021] One brand of lyocell fiber that can be used in the present
invention is 100% TENCEL.RTM. yarn from Lenzing AG. TENCEL.RTM.
cellulosic fibers are of botanic origin and have natural comfort,
strength, efficient moisture absorption and gentleness to skin.
[0022] Shown in FIG. 1 is a schematic drawing of an embodiment of
the lightweight woven sheet 100 of the present invention having a
grid construction 110. Since lighter fabrics tend to tear, this
grid construction reinforces the sheet from tearing. This produces
an overall superlight, drapey sheet.
[0023] Specifically, the sheet sample 100 in FIG. 1 comprises a
dynamic (variable) grid construction 110, combining a plain weave
120 pattern with an open dobby weave 130 pattern. The latter
creates areas of breathability and the former creates areas of
reinforcement. The fabric is woven at a low thread count using
natural, moisture absorbing fibers to encourage breathability and
moisture vapor transport.
[0024] FIG. 2 is a schematic drawing of another embodiment of the
lightweight woven sheet 200 of the present invention. The 1.times.1
plain weave section/segment (also called tabby weave, linen weave
or taffeta weave) shown as 210 is the most basic of three
fundamental types of textile weaves (along with satin weave and
twill). It is strong and hard-wearing and is used for fashion and
furnishing fabrics. In plain weave cloth, the warp and weft threads
cross at right angles, aligned so they form a simple crisscross
pattern. Each weft thread crosses the warp threads by going over
one, then under the next, and so on. The next weft thread goes
under the warp threads that its neighbor went over, and vice versa.
Balanced plain weaves, such as the 210 segment (section), are
fabrics in which the warp and weft are made of threads of the same
weight (size) and the same number of ends per inch as picks per
inch. A balanced plain weave can be identified by its
checkerboard-like appearance. It is also known as one-up-one-down
weave or over-and-under pattern. This results in a matte finish
with a cool, crisp feel.
[0025] The 2.times.2 basket weave section/segment (or matt weave)
shown as 220 is not tightly woven and is often produced on a dobby
loom. This creates a dobby weave, which is characterized by small,
repeating geometric patterns and extra texture in the cloth.
Depending on the thread count, fiber and other properties, dobby
weave results in breathable open constructions. This leaves open
holes that allows breathability through physical construction.
[0026] This type of weave is constructed by extending the plain
weave in warp and weft directions at the same time so that two or
more threads work alike in both directions. In this weave, the same
size of squares appears on both sides of the fabric showing the
same number of warp and weft yarns on front and back of the fabric.
This weave requires a minimum of two heald frames.
[0027] In FIG. 2, the 2.times.2 basket weave creates two separate
geometric patterns of breathable area.
[0028] FIG. 3 shows an enlarged view of an area identified by
reference 230 in FIG. 2. Here, segment 310 shows an enlarged view
of the 1.times.1 plain weave segment (of FIG. 2), comprising the
higher density segment of the presently shown pattern. In turn,
segment 320 shows an enlarged view of the 2.times.2 basket weave
segment (of FIG. 2), which is not as tightly woven as segment 310
(i.e., it is a lower density segment then segment 310). The created
dobby weave generates extra texture in the cloth, and attractive
geometric patterns which could be paced as shown in segments 320
and 330, for example, leading to higher sheet breathability in
areas 320 and 330 of the sheet.
[0029] This invention provides numerous advantages: the less
tightly woven sections of the sheet reduce the overall weight of
the material per unit area (e.g., square foot or square meter). In
addition, the less tight weaves increase breathability of the
fabric. The lightweight and breathable characteristics of the sheet
make is perfect for bedding applications, such as bedsheets, duvet
inserts, quilts, pillows, pillowcases, mattress covers, and other
bedding products.
[0030] The invented sheet allows it to be over 6 times more
breathable than a typical 1.times.1 percale fabric, while also
improving upon the tear and breaking strength. (Percale is a type
of weave used to make sheets, towels, and other types of bedding.)
Despite its relatively low thread count, the quality and durability
of the sheet is maintained.
[0031] Features of this lightweight, breathable woven sheet may
include: [0032] Yarn size may be 40.times.40, 60.times.60 or
80.times.80. [0033] The weight of approximately 85 g/m.sup.2, which
is about 30 to 50 g/m.sup.2 lighter than conventional sheeting
fabrics.
[0034] Alternatives of 100% lyocell for this lightweight woven
sheet include the following fabrics: Organic Cotton/Conventional
Cotton/Recycled Cotton; Linen; Hemp; Recycled
Polyester/Conventional Polyester; Recycled Nylon/Conventional
Nylon; Wool; Cashmere; Alpaca; or blends of 2 or more of the above
fibers.
[0035] Table 1 below shows a comparison and illustrates the
advantages of the present invention over the prior art (such as OLD
SUPIMA PERCALE, SATEEN, PERCALE). As can be seen from the table,
the invention implemented achieves a significantly lighter weight
than the prior art, combined with a higher breathability.
TABLE-US-00001 TABLE 1 BREATHABILITY THREAD WEIGHT (Cubic Feet per
NAME CONTENT CONSTRUCTION COUNT (g/m.sup.2) Minute) OLD 100% 1
.times. 1 Percale 400 TC 128 16 SUPIMA Supima 2/80 .times. 2/80
PERCALE Cotton [2-ply 80's yarn] 110 warp threads .times. 90 weft
threads SATEEN 100% 3 .times. 1 Sateen 276 TC 116 93.7 GOTS 60
.times. 60 yarn Organic 185 warp threads .times. Cotton 91 weft
threads PERCALE 100% 1 .times. 1 Percale 300 TC 90 30 Organic 80
.times. 80 yarn Cotton 185 warp threads .times. 115 weft threads
Present 100% Dobby Check 202 TC 85 304 Invention Tencel 60 .times.
60 yarn 108 warp thread .times. 94 weft threads
[0036] FIG. 4 discloses the low shrinkage and good shagging
resistance of the fabric made according to the present invention
when tested according with the AATCC 135-18t and ASTM D5362-13
(R2018) specifications, respectively, both of which are
incorporated herein by reference. As can be seen from FIG. 4, for
the first 1-5 wash cycles, the invented sheet shows very slight
shrinkage, both lengthwise and width-wise. However, after 5 and
more wash cycles, there is no further shrinkage. As a result, the
shrinkage becomes limited to 5.0% length-wise, and at 2.0%
width-wise.
[0037] FIG. 4 also shows that the invented sheet can achieve an
average shagging grade of 3.5 in both front and back surfaces.
[0038] FIG. 5 discloses the good air permeability and excellent
piling resistance of the lightweight breathable sheet made
according to the present invention (with yearn number tested per
ASTM D1059-17) when tested according with the ASTM D737-18
(permeability), ASTM D4970-16E3 (piling resistance), and
ASTMD3512-16 (piling resistance) specifications, each of which is
incorporated herein by reference. For example, the invented sheet
can maintain an average piling grade of 4.0 even after 1000 cycles
per the ASTM D4970-16E3 specification, and a piling grade of 4.5
after 60 min. per the ASTM D3512-16 specification, mining the
fabric's piling characteristic is between slight piling and no
piling.
[0039] FIG. 6 discloses the tearing strength and breaking strength
of the lightweight breathable sheet made according to the present
invention when tested according with the ASTM 2261-13(R2017)E1
(tearing strength) and ASTM D5034-09(R2017) (breaking strength).
(The thread-count of 202, based on average ends and average picks
per D3775-17e1 and wight, according to ASTM D3776-09A(R2017) Option
C, of 85 g/square meter.) Each of the above specification is
incorporated herein by reference. FIG. 6 shows the tearing strength
of the sheet being 10.5 lbs in the warp direction and 10.3 lbs in
the weft direction. The Figure also shows the braking strength of
the sheet being 65 lbs in the warp direction and 48.3 lbs in the
weft direction. All of these results indicate that the invented
sheet is durable while both lightweight and breathable.
[0040] In the foregoing specification, specific embodiments have
been described. However, one of ordinary skill in the art
appreciates that various modifications and changes can be made
without departing from the scope of the invention as set forth in
the claims below. Accordingly, the specification and figures are to
be regarded in an illustrative rather than a restrictive sense, and
all such modifications are intended to be included within the scope
of present teachings.
[0041] The benefits, advantages, solutions to problems, and any
element(s) that may cause any benefit, advantage, or solution to
occur or become more pronounced are not to be construed as a
critical, required, or essential features or elements of any or all
the claims. The invention is defined solely by the appended claims
including any amendments made during the pendency of this
application and all equivalents of those claims as issued.
[0042] Unless stated otherwise, terms such as "first" and "second"
are used to arbitrarily distinguish between the elements such terms
describe. Thus, these terms are not necessarily intended to
indicate temporal or other prioritization of such elements.
[0043] Unless otherwise stated, conditional languages such as
"can", "could", "will", "might", or "may" are understood within the
context as used in general to convey that certain embodiments
include, while other embodiments do not include, certain features
and/or elements. Thus, such conditional languages are not generally
intended to imply that features and/or elements are in any way
required for one or more embodiments.
[0044] It will be understood by those within the art that, in
general, terms used herein, are generally intended as "open" terms
(e.g., the term "including" should be interpreted as "including but
not limited to", the term "having" should be interpreted as "having
at least", the term "includes" should be interpreted as "includes
but is not limited to", etc.). The term "coupled" should be
interpreted to include both direct and indirect coupling.
* * * * *