High-density warp-fiber woven fabric and methods of manufacturing the same

Abstract

A high thread count woven fabric for use in bedding products includes a 5-end sateen weave formed from a plurality of interwoven cotton warp and weft threads, wherein the number of warp threads per square inch of the fabric is at least about 240 and the number of the weft threads per square inch is about 9% to about 21% A higher than in conventional high thread count fabrics. A method of making the high thread count fabric includes setting up a weaving machine with a shed height and a backrest adjustment as described and shown herein to facilitate weaving the fabric with the high density of warp threads.

What is claimed is: 
     
         1 . A high thread count fabric comprising a 5 end sateen weave formed from a plurality of interwoven warp and weft threads, the warp threads comprising at least about 65% of the number of weft threads per one square inch of fabric. 
     
     
         2 . A high thread count flat woven bedding product made from the fabric of  claim 1 . 
     
     
         3 . A method of making the fabric of  claim 1 , including setting up a weaving machine with a shed height and a backrest adjustment as described and shown herein. 
     
     
         4 . A method of making the fabric of  claim 1 , comprising a surface index value ranging from 2.2 to 2.5 which is achieved by using yarn in a higher density. 
     
     
         5 . A method of making the fabric of  claim 1 , wherein in order to control vibration in warp sheet and warp breakage in higher thread density flat fabric level  2  is to be selected to weave the fabric on a weaving machine. 
     
     
         6 . A method of making the fabric of  claim 1 , wherein a frame to frame crossing position is kept at 290 to 300 compared to 300 to 310 in conventional flat woven fabric like sateen or satin. 
     
     
         7 . A method of making the fabric of  claim 1 , wherein a long lasting sheen is achieved by using a higher number of threads per inch in warp compared to conventional sateen sheets. 
     
     
         8 . A method of making the fabric of  claim 1 , wherein a silk kind of sheen is achieved in a 100% cotton or cotton blended flat woven fabric like sateen or satin. 
     
     
         9 . A high density warp fiber fabric comprising a thread count of at least 400 and a surface index value between 1.95 and 2.20, inclusively. 
     
     
         10 . A high density warp fiber fabric of  claim 9 , further comprising a warp-thread density between 240 warp threads per inch and 260 warp threads per inch, inclusively. 
     
     
         11 . A high density warp fiber fabric of  claim 9 , further comprising a weft-thread density between 325 weft threads per inch and 355 weft threads per inch, inclusively. 
     
     
         12 . A high density warp fiber fabric of  claim 9 , further comprising a denting order of 5 warp per dent. 
     
     
         13 . A method of fabricating the fabric of  claim 9 , including a weaving setting wherein the weaving setting comprising a shed height between 55 mm and 60 mm, a backrest between 35 mm and 45 mm, a frame-to-frame crossing position between 290 and 300. 
     
     
         14 . A method of fabricating the fabric of  claim 12 , the weave setting further comprising a 5-end sateen weave configuration. 
     
     
         15 . A method of fabricating the fabric of  claim 12 , the weave setting further comprising a first frame heald height between 72 mm and 74 mm, a second frame heald height between 70 mm and 72 mm, a third frame heald height between 28 mm and 70 mm, a fourth heald height between 66 mm and 70 mm, and a fifth heald height of 72 mm. 
     
     
         16 . A method of fabricating a high density warp fiber fabric comprising
 selecting warp and weft fibers for weaving;   configuring a weaving machine, wherein configuring the weaving machine includes setting a weave configuration as a 5-end sateen weave;   weaving the fibers into an unfinished high thread count fabric; and   finishing the high thread count fabric.   
     
     
         17 . A method of fabricating a high density warp fiber fabric of  claim 16 , wherein configuring the weaving machine further includes setting a shed height adjustment between 55 mm and 60 mm. 
     
     
         18 . A method of fabricating a high density warp fiber fabric of  claim 16 , wherein configuring the weaving machine further includes setting a backrest adjustment between 35 mm and 45 mm. 
     
     
         19 . A method of fabricating a high density warp fiber fabric of  claim 16 , wherein configuring the weaving machine further includes setting a frame-to-frame crossing position between 290 and 300. 
     
     
         20 . A method of fabricating a high density warp fiber fabric of  claim 16 , wherein configuring the weaving machine further includes setting a first frame heald height between 72 mm and 74 mm, a second frame heald height between 70 mm and 72 mm, a third frame heald height between 28 mm and 70 mm, a fourth heald height between 66 mm and 70 mm, and a fifth heald height of 72 mm.