AU2019217659A1 - Improved article of bedding - Google Patents

Abstract

The present invention provides an article of bedding (such as a flat sheet or a fitted sheet) comprising a continuous piece of fabric, the article having a dimension of at least about 90 inches, wherein the fabric is elastically stretchable in more than one direction. Advantageously, the article of bedding may be devoid of any seam used to join two discrete pieces of fabric. The article of bedding may be formed by a circular knitting process using a synthetic material, or a blend of synthetic materials.

Description

IMPROVED ARTICLE OF BEDDING

FIELD OF THE INVENTION

The present invention relates to articles of bedding including but not limited to a lower sheets, an upper sheets or a pillow case. The invention extends also to methods for fabricating such articles.

BACKGROUND TO THE INVENTION

Articles of bedding such as sheets and pillow cases have been fabricated from a range of materials. Because these articles contact the skin, regard has been had by prior artisans to select materials which visually appealing, are comfortable, and generally assist in providing a restful sleep. Other issues such as cost, ease of laundering, longevity, and appearance are also typically considered in selecting a suitable fabric.

More recently, functional characteristics of bedding such as air flow and moisture wicking have been considered in selecting materials. Thus, some bedding materials are intentionally designed to improve the quality of sleep by regulating the temperature and humidity in the microenvironment about a person.

Natural fibres such as cotton have been generally preferred over the years, although prior artisans have experimented significantly with various fabrics including synthetics and semi synthetics synthetic fabrics and various blends. The use of fibres and yarns other than cotton have been found to provide functional advantages.

For bedding made of some functional materials (and particularly some synthetic and semi synthetic materials), two pieces of fabric are joined (typically by a seam) to provide an article of sufficient width to span a bed. In particular, beds that are double, queen, king size and larger require sheeting of considerable dimensions especially given the need to fold the edges under the mattress to secure. In that context, joining seams are used in the manufacture of functional articles of bedding. The necessity of including seams to join together two or more fabric portions presents a number of problems. Firstly, the inclusion of seams introduce the need for further production steps, including the expense of labour, materials and equipment. Furthermore, additional quality control measures must be instituted to ensure the seam has been properly formed. These problems are exacerbated where more than one seam is required, for example where a sheet comprises a main fabric portion and two or more smaller peripheral portions are joined thereto.

A second problem is that a join presents a line of potential failure in the article. As will be appreciated, sheets are subject to multiple rounds of laundering, being stretched over a bed, being pulled off a bed. The stresses occasioned on the seam can lead to failure, with the sheet requiring repair or to be discarded. While heavy duty stitching may be used to lower the chance of failure, such seams are aesthetically unpleasing and/or uncomfortable to lie on as discussed below.

A third problem is that the seams are aesthetically displeasing. Even fine and carefully constructed seams are visible, with more heavy duty seams being very visible. Prior artisans have recognised this problem and attempted to overcome by the incorporation of piping into the seam, so as to convert the seam into a visual feature. Alternatively, the seams may be placed in less obvious parts, such as the parts that overly the edges of the mattress upper face. Where an article of bedding is designed to drape (for example, as a bed cover or a“throw”) a seam will interfere with the visually pleasing draping effect. Consumers are very used to the aesthetic of a bedding sheet being devoid of joins of any type, and may generally avoid a sheet having seams.

A fourth problem is that a seam may be felt by a person lying on the sheets. Typically, thinner apparel or no apparel is worn in bed, and a person may become aware of the tactile sensation on the skin provided by contact with the seam. To some individuals, this can represent an annoyance to the extent that sleep is inhibited.

It is an aspect of the present invention to overcome of ameliorate a problem of the prior art by providing articles of bedding made from materials that are comfortable for the user, and also more simple and economical for the manufacturer to produce. It is a further aspect to provide an alternative to prior art articles of bedding and methods for producing same. The discussion of documents, acts, materials, devices, articles and the like is included in this specification solely for the purpose of providing a context for the present invention. It is not suggested or represented that any or all of these matters formed part of the prior art base or were common general knowledge in the field relevant to the present invention as it existed before the priority date of each claim of this application

SUMMARY OF THE INVENTION

After considering this summary and the following detailed description it will be apparent to one skilled in the art how the invention is implemented in various alternative embodiments and alternative applications. However, although various embodiments of the present invention will be described herein, it is understood that these embodiments are presented by way of example only, and not limitation. As such, this description of various alternative embodiments should not be construed to limit the scope or breadth of the present invention. Furthermore, statements of advantages or other aspects apply to specific exemplary embodiments, and not necessarily to all embodiments covered by the claims.

Throughout the description and the claims of this specification the word "comprise" and variations of the word, such as "comprising" and "comprises" is not intended to exclude other additives, components, integers or steps.

Reference throughout this specification to“one embodiment” or“an embodiment” means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment” or“in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment, but may.

In this specification, length measurements are cited in both centimetres and inches. This approach is not intended to introduce any lack of clarity into the description of the invention or the scope of the claims, but is used to reflect industry norms for using inches in the knitting industry (for example citing gauge by way of needles per inch) and also the measurement of fabrics, articles of bedding, and mattress sizes in centimetres and inches dependent on the countries or region concerned.

In a first aspect, but not necessarily the broadest aspect, the present invention provides an article of bedding comprising a continuous piece of fabric, the article having a dimension of at least about 90 inches, wherein the fabric is elastically stretchable in more than one direction. In order to produce an article of that minimum dimension, it may be necessary for the continuous piece of fabric to initially be of greater dimension considering the possibility of a hem, or multiple hems on the finished article. For example, a flat sheet may have a large hem (say, 4 inches deep) along a short end (such as the head end) meaning that the continuous piece of fabric must has a dimension of at least 94 inches in order to accommodate the hem. Smaller hems (less than one inch) may also be disposed along the remaining three edges, meaning that at least in the long dimension the continuous piece of fabric used to product the article of bedding must be at least 95 inches long.

The dimension of the continuous piece of may be a length or a width of the bed sheet, depending upon the configuration of the bed for which the article is intended to be fitted.

Suitably, the article of bedding is dimensioned so as to capable of fitting any one or more of one of the many standard sizes of mattress sold that require a sheet having a dimension of at least 90 inches ; and in particular the North American sizes of Twin extra long ((39 in x 80 in (99 cm x 203 cm)), Three quarter ((48 in x 75 in (122 cm x 190 cm) often (47-48) in x 72 in), Super single (48 in x 84 in (122 cm x 213 cm)), Full extra long (53 in x 80 in), Olympic queen (66 in x 80 in (168 cm x 203 cm)), California queen (60 in x 84 in (152 cm x 213 cm)), Eastern king (76 in x 80 in (193 cm x 203 cm)), California king (72 in x 84 in (183 cm x 213 cm), Standard double (4'6" x 6'3", also sold as 135 cm by 190 cm), King (5' x 6'6", also sold as 150 cm by 200 cm), Super King (6' x 6'6", also sold as 180 cm by 200 cm), Eastern king (78 in (200 cm) wide), Emperor (84 in (210 cm) wide) and 'Caesar' (96 in (240 cm) wide); Mainland European sizes of Piazza francese (140 cm (55 in) wide), Due piazze or Matrimoniale (160- 180 cm (63-71 in) wide), Tre piazze or Osimano (200-400 cm (79-157 in) wide); Norwegian sizes: Queen (150 cm x 200 cm (60 in x 79 in)), King (180 cm x 200 cm (71 in x 79 in)); Australian sizes: Double (137 cm x 187 cm (54 in x 74 in)), Queen (153 cm x 203 cm (60 in x 80 in)), King (183 cm x 203 cm (72 in x 80 in)); New Zealand sizes: Double (135 cm x 190 cm (53 in x 72 in)), Queen (152 cm x 203 cm (60 in x 80 in)), King (165 cm x 203 cm (65 in x 80 in)), Super king (180 cm x 203 cm (71 in x 80 in)), Californian king (200 cm x 203 cm (79 in x 80 in)).

As will be appreciated, the article will be of greater dimension than any of the mattress measurements recited above given the need for extra fabric to extend downwardly along the side faces of the mattress, and also fold under the mattress to be retained thereby. For a fitted sheet, only a very small area of fabric ends up under the mattress, however for a flat sheet, it is preferred that at least about 1, 2, 3, 4, 5, 6, 7, 8, 9 or 10 inches is allowed. The extra fabric may add about 5, 10, 15, 20, 25, 30, 35, 40, 45, 50 inches to any of the mattress dimensions recited supra.

In one embodiment, the article of bedding has a dimension of greater than about 91, 92, 93, 94, 95, 96, 97, 98, 99, 100, 101, 102, 103, 104, 105, 106, 107, 108, 109, 110, 111, 112, 113, 114, 115, 116, 117, 118, 119, 120, 121, 122, 123, 124, 125, 126, 127, 128, 129, 130, 131, 132, 133, 134, 135, 136, 137, 138, 139, 140, 141, 142, 143, 144, 145, 146, 147, 148, 149 or 150 inches.

In one embodiment of the first aspect, the article of bedding is devoid of a seam used to join two discrete pieces of fabric. As referenced in the Background section herein, some sheets of the prior art are fabricated by joining together two discrete pieces of fabric in order to provide sufficient width or length for the intended use. The present invention provides means for providing a sufficiently dimensioned continuous fabric so as to avoid the need for any such joining.

It will be appreciated however, that an article of bedding of the present invention may comprise a join between two edges of a single continuous piece of material. For example, where the article is a fitted bed sheet, a region of fabric at each corner of the continuous piece of fabric is removed and the edges bordering the cut out are brought together and joined by stitching to form a pocket configured to fit over a corner region of a mattress. This type of joining is, at least in the context of the present invention, not considered to be a join between two discrete pieces of fabric. In one embodiment of the first aspect, the continuous piece of fabric is devoid of a seam used to join two discrete pieces of fabric and the continuous piece of fabric has an area of at least about 90% of the area of the article of bedding. In another embodiment of the first aspect, the continuous piece of fabric is devoid of a seam used to join two discrete pieces of fabric and the continuous piece of fabric has an area of at least about 95% of the area of the article of bedding. Areas of at least about 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 91, 92, 93, 94, 96, 97, 98, 99% or about 100% are contemplated to be useful. While the present article may comprise a second fabric portion joined to the continuous fabric portion, it will be generally the case that any second fabric portion is of considerably smaller area than that of the continuous fabric portion. In that record, the continuous fabric portion may be considered a main fabric portion of any article of bedding produced therefrom.

In one embodiment of the first aspect, the continuous piece of fabric has been formed by a circular knitting process. Industrial high speed circular knitting machines are known in the art for their ability to produce large areas of fabric quickly and cost effectively. In these machines, a plurality of individual yarns are fed directly into a needle bed that spins unidirectionally so as to create a tube of fabric through the centre of the machine. The tube is subsequently cut longitudinally so as to form a flat sheet of fabric. The circular knitting apparatus and/or knitting methods of the prior art have failed to produce a fabric that, at least in finished form, is of sufficient dimension to produce an article of bedding having a dimension of at least about 90 inches.

In one embodiment of the first aspect, the circular knitting process is a weft knitting process. The weft knitting process may be used to produce a rib knit (a combination of knit and purl stitches); a purl knit (which is made with purl stitches alone), or a jersey knit (made with knits stitches on the front and purl stitches on the reverse side). The jersey knit may be selected from the group consisting of a single jersey knit, a double jersey knit, and interlock jersey knit, a jacquard jersey knit, a clocque jersey knit or a stretch jersey knit. It has been found that a single jersey knit is preferred given the relatively large areas of fabric used in the present articles of bedding. Single jersey knit fabrics are relatively light in weight and therefore more suitable for bedding compared with more heavy duty knits. A light weight fabric is particularly preferred where the bedding is designed to have functional aspects such as facilitating air circulation and moister wicking. These functions may assist in lowering body temperature, which in turn assists in sleeping.

A single jersey knit may also provide for a fabric that contracts less during production or finishing so as to facilitate maximizing a dimension thereof.

In one embodiment of the first aspect, the circular knitting process is executed on a circular knitting machine having a diameter of about diameter of at least about 30, 31, 32, 33, 34, 35, 36, 37 or 38 inches. The diameter may be still higher at about 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49 or 50 inches.

In one embodiment of the first aspect, the circular knitting machine has a gauge of at least about 17 needles per inch. Higher gauges such as 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, or 36 are preferred given the finer knit resulting. It has been found that a finer knit is particularly suited to producing the relatively large dimension continuous pieces of fabric needed to manufacture the seamless articles of bedding of the present invention. Fine knits also provide for improved aesthetics and draping as compared lower gauge knits. Machines having still higher gauges of 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49 or 50 needles per inch will also be useful or even advantageous in the context of the present invention.

In one embodiment of the first aspect, the continuous piece of fabric is knitted from a synthetic material, or a blend of synthetic materials. Synthetic materials are useful in so far as a capillary action may be provided in the resultant fabric, helping to wick perspiration away from a sleeping individual. Some synthetic materials may also allow for the resultant fabric to exhibit a relatively high degree of elastic stretchability, and particularly omnidirectional elastic stretchability. Omnidirectional elastic stretchability is a useful property in sheeting, and especially in respect of fitted sheets given the ability of the article to stretch over and conform closely to the shape of a mattress. A fitted sheet having omnidirectional elastic stretchability is more likely to remain taught and therefore avoid wrinkles and folds which may be felt by a user. In one embodiment of the first aspect, the synthetic material consists of or comprises a synthetic fibre or a synthetic yarn. In some embodiments, a single fibre may be used (for example Elastane™), while for other embodiments a yarn comprises of filaments is used (such as polyester).

Synthetic fibres and yarns may be chosen according to some functional property (such as weight, elastic stretchability, ability to take a dye, durability, fineness, and softness), or an aesthetic property. Synthetics including rayon, nylon, polyester, acrylic, modacrylic are all available to the skilled person as being potentially useful in the context of the present invention.

In one embodiment of the first aspect, the synthetic yarn is comprised of polyester fibres.

In one embodiment of the first aspect, the synthetic yarn or fibre (irrespective of its chemical composition) is between about 50 Denier and 150 Denier, or between about 90 Denier and 110 Denier. Embodiments where the synthetic yarn is 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61,

62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86.

87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 100, 101, 102, 103, 104, 105, 106, 107, 108,

109, 110, 111, 112, 113, 114, 115, 116, 117, 118, 119, 120, 121, 122, 123, 124, 125, 126, 127,

128, 129, 130, 131, 132, 133, 134, 135, 136, 137, 138, 139, 140, 141, 142, 143, 144, 145, 146,

147, 148, 149, or 150 Denier are contemplated to be useful, or even advantageous.

In one embodiment of the first aspect, the synthetic yarn or fibre comprises from about 100 filaments to about 200 filaments. Embodiments having a filament number of 100, 101, 102, 103, 104, 105, 106, 107, 108, 109, 110, 111, 112, 113, 114, 115, 116, 117, 118, 119, 120, 121,

122, 123, 124, 125, 126, 127, 128, 129, 130, 131, 132, 133, 134, 135, 136, 137, 138, 139, 140,

141, 142, 143, 144, 145, 146, 147, 148, 149, 150, 151, 152, 153, 154, 155, 156, 157, 158, 159,

160, 161, 162, 163, 164, 165, 166, 167, 168, 169, 170, 171, 172, 173, 174, 175, 176, 177, 178,

179, 180, 181, 182, 183, 184, 185, 186, 187, 188, 189, 190, 191, 192, 193, 194, 195, 196, 197,

198, 199, or 200 may be useful, or even advantageous.

As will be understood, various combinations of filament numbers can be used to provide a yarn having a required Denier, as illustrated in the Table below.

In one embodiment of the first aspect, the synthetic fibre or synthetic yarn is elastically stretchable. As used herein, the term“elastically stretchable” means that the fibre or yarn may be stretched and then return to substantially its original length of its own accord. Preferably, the synthetic fibre or yarn may be stretched at least lO-fold, lOO-fold, 200-fold, 300-fold, 400- fold, or 500-fold its original length.

In one embodiment of the first aspect, the synthetic fibre is a copolymer of polyether and polyuria, this fibre often sold under the trade names of Elastane™, Spandex™ and Lycra™. Also contemplated is a relatviely new biconstituent fiber sold under the trade name Monvelle™, being a a side-by-side bicomponent fiber containing nylon and spandex. The fiber is melt spun by special spinnerets to form the fiber. Also generally less preferred due to a low resistance to chemical attack, rubber fibres such as those sold under the trade names Buthane™, Contro™, Hi-Flex™, Lactron™, Lastex™, and Laton™ may be used

In one embodiment of the first aspect, the synthetic fibre is. between about 20 Denier and 60 Denier such as 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, may be used. Spandex™ fibres of about 40 Denier are particularly preferred.

In one embodiment of the first aspect, the blend of synthetic materials comprises an elastically stretchable material and a substantially non-elastically stretchable material. Such composites are generally preferred, with the proportion of the substantially non-elastically stretchable material in the blend of synthetic materials generally being higher than that for the elastically stretchable material. In one embodiment of the first aspect, the proportion of the substantially non-elastically stretchable material in the blend of synthetic materials is at least about five-fold that for the elastically stretchable material, although may be at least about six-fold, seven-fold, 8-fold, 9- fold or ten-fold. In one embodiment of the first aspect, the proportion of the substantially non- elastically stretchable material in the blend of synthetic materials is at least about eight-fold that for the elastically stretchable material. In alternative terms, the elastically stretchable material may be present at least about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19 or 20%. Higher proportions of an elastically stretchable fibre or yarn can lead to an unwanted reduction in the maximum width available for the finished fabric, and in turn a lower than required width for the continuous piece of the fabric used in production of the present article. However, lower proportions of the elastically stretchable fibre can lead to an article that has insufficient stretch to conform about a mattress, or otherwise have less desirable characteristics. At least so far as Spandex™ is concerned, it has been found that a proportion of 10% provides an acceptable balance.

In one embodiment of the first aspect, the substantially non-elastically stretchable material is a polyester yarn, and the elastically stretchable material is a fibre being a copolymer of polyether and polyurea.

Any knitting parameter above and/or any material parameter discussed above may be manipulated (alone, or in combination with other parameters) to maximize the finished width of the circular knitted fabric.

In one embodiment of the first aspect, the article of bedding is a flat bed sheet or a fitted bed sheet. According to such embodiments the article of bedding may have: a hem along at least one edge, or along all edges; or a corner pocket; or an elastic along an edge, or a draw string about the circumference, or a fabric or non-fabric tie configured to retain the sheet on a bed.

In a second aspect, the present invention provides a method for producing an article of bedding, the method comprising the steps of: providing a continuous piece of fabric that is elastically stretchable in more than one direction, cutting the fabric according to a template, and sewing the fabric to form a hem or a corner pocket, wherein the article of bedding has a dimension of at least about 90 inches.

As will be appreciated, any details pertaining to the knitting or material parameters described supra in respect of the article of bedding (being the first aspect of the invention) are relevant also to the methods of the second aspect. For example, a parameter such as the knitting machine diameter, knitting machine gauge, material, yarn, fibre, proportion of materials and the like may be applied to the same parameters when used to define the methods of the second aspect. For the sake of clarity and brevity such details will not be repeated below in defining the methods of the second aspect, however it will be understood that such details are applicable thereto.

In one embodiment of the second aspect, the method is devoid of the step of forming a seam to join two discrete pieces of fabric.

In one embodiment of the second aspect, the template is configured such that the continuous piece of fabric has an area of at least about 90% of the area of the article of bedding.

In one embodiment of the second aspect, the template is configured such that the continuous piece of fabric has an area of at least about 95% of the area of the article of bedding.

In one embodiment of the second aspect, the continuous piece of fabric has been formed by a circular knitting process.

In one embodiment of the second aspect, the circular knitting process is a weft knitting process.

In one embodiment of the second aspect, the weft knitting process is a jersey knitting process.

In one embodiment of the second aspect, the jersey knitting process is a single jersey knitting process.

In one embodiment of the second aspect, the circular knitting process has been executed on a circular knitting machine having a diameter of about diameter 38 inches or greater. In one embodiment of the second aspect, the circular knitting machine has a gauge of at least about 17 needles per inch.

In one embodiment of the second aspect, the circular knitting machine has a gauge of at least about 30 needles per inch.

In one embodiment of the second aspect, the circular knitting machine has a gauge of at least about 36 needles per inch.

In one embodiment of the second aspect, the continuous piece of fabric is knitted from a synthetic material, or a blend of synthetic materials.

In one embodiment of the second aspect, the synthetic material consists of or comprises a synthetic fibre or a synthetic yarn.

In one embodiment of the second aspect, the synthetic yarn is comprised of polyester fibres.

In one embodiment of the second aspect, the synthetic yarn is between about 50 Denier and 150 Denier.

In one embodiment of the second aspect, the synthetic yarn is between about 90 Denier and 110 Denier.

In one embodiment of the second aspect, the synthetic yarn comprises from about 100 filaments to about 200 filaments.

In one embodiment of the second aspect, the synthetic fibre or synthetic yarn is elastically stretchable.

In one embodiment of the second aspect, the synthetic fibre is a copolymer of polyether and polyurea. In one embodiment of the second aspect, the synthetic fibre is between about 20 Denier and 60 Denier

In one embodiment of the second aspect, the blend of synthetic materials comprises an elastically stretchable material and a substantially non-elastically stretchable material.

In one embodiment of the second aspect, the proportion of the substantially non-elastically stretchable material in the blend of synthetic materials in higher that for the elastically stretchable material.

In one embodiment of the second aspect, the proportion of the substantially non-elastically stretchable material in the blend of synthetic materials is at least about five-fold that for the elastically stretchable material.

In one embodiment of the second aspect, the proportion of the substantially non-elastically stretchable material in the blend of synthetic materials is at least about eight-fold that for the elastically stretchable material.

In one embodiment of the second aspect, the substantially non-elastically stretchable material is a polyester yarn, and the elastically stretchable material is a fibre of a copolymer of polyether and polyurea.

In one embodiment of the second aspect, the method comprises the step of modifying the continuous piece of fabric cut from the template to form a flat bed sheet or a fitted bed sheet.

In one embodiment of the second aspect, the step of modifying the continuous piece of fabric comprises the step of: forming of a hem along at least one edge, or along all edges of the continuous piece of fabric cut from the template; or forming a corner pocket on the continuous piece of fabric cut from the template; or securing an elastic along an edge of the continuous piece of fabric cut from the template.

The present invention is more fully described infra, and with reference to the drawings. BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a flowchart detailing the process steps in processing grey fabric received from knitting mill to provide a finished fabric.

FIG. 2 is a flowchart detailing the process steps in processing finished fabric received from knitting mill.

FIG. 3 A is a photograph of a continuous piece of fabric cut according to a Queen flat sheet template.

FIG. 3B is a photograph of a continuous piece of fabric cut according to a Queen fitted sheet template.

FIG. 3C is a photograph of a continuous piece of fabric cut according to a pillowcase template.

FIG. 4A is a diagrammatic representation of the flat sheet produced from the cutted piece shown in FIG. 3 A. The dimensions shown are exemplary and not intended to be limiting.

FIG. 4B is a diagrammatic representation of the flat sheet produced from the cutted piece shown in FIG. 3B. The dimensions shown are exemplary and not intended to be limiting.

FIG. 4C is a diagrammatic representation of the flat sheet produced from the cutted piece shown in FIG. 3C. The dimensions shown are exemplary and not intended to be limiting.

DETAILED DESCRIPTION OF THE INVENTION AND PREFERRED

EMBODIMENTS THEREOF

Applicant has found that a bed sheet having functional characteristics such as improved moisture wicking or air flow or heat transfer can be produced without the need to join together two portions of fabric. Flat and fitted Sheets capable of fitting mattress of double bed size and larger may be produced without the problems caused by seams as detailed in the Background section herein.

It has been found that a circularly knitted synthetic fabric can be produced as a single continuous piece, while still being of a widths useful in making a bed sheet, and without the need to join together two discrete portions of fabric.

EXAMPLE 1 : PRODUCTION OF SHEET AND PILLOWCASE SET SUITABLE FOR

AUSTRALIAN QUEEN SIZED MATTRESS.

A continuous fabric was prepared from a blend of 90% polyester yarn and 10% Spandex™ fibre. The polyester yarn was comprised of 144 filaments, and was of 100 Denier. The Spandex™ was 40 Denier.

According to methods well known in the art of textile knitting, the polyester and Spandex™ materials were fed into a single Jersey high speed circular knitting machine of 38 inch diameter and a gauge of 36 needles/inch.

The machine produced a grey fabric of width 220 cm to 230 cm.

Reference is now made to FIG. 1 which outlines the process steps involved in finishing the grey fabric.

In terms of processing, the grey fabric was firstly unpacked and then washed in hot water.

The circular fabric was cut longitudinally to form a flat piece of fabric.

The flat fabric was then set to the width for dyeing (disperse dyeing was used in this embodiment). After washing and dewatering steps, the fabric was treated with a moisture wicking agent (the 3M Company, USA) during heat setting. While the grey fabric has some wicking ability, this is enhanced by the further treatment. The finished fabric width was 258 cm.

After final inspection and packing, the fabric was sent to a stitching mill for production of articles of bedding as described infra. Reference is now made to FIG. 2 which outlines the process steps involved in producing the articles of bedding, being (i) a flat sheet, (ii) a fitted sheet, and (iii) a pillowcase.

After unpacking, the finished fabric the finish fabric was laid on a cutting table and cut according to a template for a flat sheet (cutted piece shown in FIG. 3 A), a fitted sheet (cutted piece shown in FIG. 3B) and a pillowcase (cutted piece shown in FIG. 3C).

For the flat sheet, hems were stitched to produce the final article, as shown in FIG. 4A.

For the fitted sheet, elastic was secured within a hem about the periphery as shown in FIG. 4B. Additionally, pockets were formed at each corner by stitching as is well known in the art.

The pillow case was constructed by means well known to the skilled person, so as to take the final form shown in FIG. 4C. It will be appreciated that in the description of exemplary embodiments of the invention, various features of the invention are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure and aiding in the understanding of one or more of the various inventive aspects. This method of disclosure, however, is not to be interpreted as reflecting an intention that the claimed invention requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment. Furthermore, while some embodiments described herein include some but not other features included in other embodiments, combinations of features of different embodiments are meant to be within the scope of the invention, and form different embodiments, as would be understood by those in the art. For example, in the following claims, any of the claimed embodiments can be used in any combination.

In the description provided herein, numerous specific details are set forth. However, it is understood that embodiments of the invention may be practiced without these specific details. In other instances, well-known methods, structures and techniques have not been shown in detail in order not to obscure an understanding of this description.

Thus, while there has been described what are believed to be the preferred embodiments of the invention, those skilled in the art will recognize that other and further modifications may be made thereto without departing from the spirit of the invention, and it is intended to claim all such changes and modifications as fall within the scope of the invention. Although the invention has been described with reference to specific examples, it will be appreciated by those skilled in the art that the invention may be embodied in many other forms.

Claims (27)

1. An article of bedding comprising a continuous piece of fabric, the article having a dimension of at least about 90 inches, wherein the fabric is elastically stretchable in more than one direction.

2. The article of bedding of claim 1 that is devoid of a seam used to join two discrete pieces of fabric.

3. The article of bedding of claim 1 or claim 2, wherein the continuous piece of fabric is devoid of a seam used to join two discrete pieces of fabric and the continuous piece of fabric has an area of at least about 90% of the area of the article of bedding.

4. The article of bedding of any one of claims 1 to 3, wherein the continuous piece of fabric has been formed by a circular knitting process.

5. The article of bedding of claim 4, wherein the circular knitting process has been executed on a circular knitting machine having a diameter of about diameter 38 inches or greater.

6. The article of bedding of claim 5, wherein the circular knitting machine has a gauge of at least about 17 needles per inch.

7. The article of bedding of any one of claims 1 to 6, wherein the continuous piece of fabric is knitted from a synthetic material, or a blend of synthetic materials.

8. The article of bedding of claim 7, wherein the synthetic material consists of or comprises a synthetic fibre or a synthetic yarn.

9. The article of bedding of claim 8, wherein the synthetic yarn is comprised of polyester fibres.

10. The article of bedding of claim 8 or claim 9, wherein the synthetic yarn is between about 50 Denier and 150 Denier.

11. The article of bedding of claim 9 or claim 10, wherein the synthetic yarn comprises from about 100 filaments to about 200 filaments.

12. The article of any one of claims 8 to 11, wherein the synthetic fibre or synthetic yarn is elastically stretchable.

13. The article of bedding of claim 12, wherein the synthetic fibre is between about 20

Denier and 60 Denier

14. The article of bedding of any one of claims 7 to 13, wherein the blend of synthetic materials comprises an elastically stretchable material and a substantially non-elastically stretchable material.

15. The article of bedding of any one of claims 1 to 14 that is a flat bed sheet or a fitted bed sheet.

16. A method for producing an article of bedding, the method comprising the steps of: providing a continuous piece of fabric that is elastically stretchable in more than one direction,

cutting the fabric according to a template, and

sewing the fabric to form a hem or a corner pocket,

wherein the article of bedding has a dimension of at least about 90 inches.

17. The method claim 16 that is devoid of the step of forming a seam to join two discrete pieces of fabric.

18. The method of claim 16 or claim 17, wherein the template is configured such that the continuous piece of fabric has an area of at least about 90% of the area of the article of bedding.

19. The method of any one of claims 16 to 18, wherein the continuous piece of fabric has been formed by a circular knitting process.

20. The method of claim 19, wherein the circular knitting process has been executed on a circular knitting machine having a diameter of about diameter 38 inches or greater.

21. The method of claim 20, wherein the circular knitting machine has a gauge of at least about 17 needles per inch.

22. The method of any one of claims 16 to 21, wherein the continuous piece of fabric is knitted from a synthetic material, or a blend of synthetic materials.

23. The method of any one of claims 16 to 22, wherein the synthetic material consists of or comprises a synthetic fibre or a synthetic yarn.

24. The method of claim 23, wherein the synthetic yarn comprises from about 100 filaments to about 200 filaments.

25. The method of claim 23 or claim 24, wherein the synthetic fibre or synthetic yarn is elastically stretchable.

26. The method of any one of claims 22 to 25, wherein the blend of synthetic materials comprises an elastically stretchable material and a substantially non-elastically stretchable material.

27. The method of any one of claims 16 to 26 comprising the step of modifying the continuous piece of fabric cut from the template to form a flat bed sheet or a fitted bed sheet.