Flat woven fabric with durable drop area, and related processes

Abstract

Woven sheets, more particularly to fitted sheets having a woven fabric top cover to cover the top surface of a mattress, and drop area for fitting around all the four sides and corners of the mattress. The woven fabric for the top cover is consisting of flat fabric of natural fiber and/or natural fiber blends and/or natural and manmade fiber blends. The woven fabric for the drop area is consisting of flat fabric of manmade fiber and/or manmade fiber blends. The drop area is stitched around the top cover. The stitched woven sheet is sustainable, economic, quick dry, durable and suitable for bedding applications.

1 . A bedding article, comprising:
 a top cover having a perimeter and formed from a first flat woven fabric, the first flat woven fabric having a warp component including warp yarns and a weft component including weft yarns interwoven with the warp yarns to define the flat woven fabric, wherein at least one of a) the warp component and b) the weft component comprise a plurality of the staple spun yarns; and   a durable drop area with quick dry property stitched to the perimeter of the top cover, the drop area formed from a second flat woven fabric that is different from the first woven fabric, the second flat woven fabric having a warp component including warp yarns and a weft component including weft yarns interwoven with the warp yarns to define the flat woven fabric, wherein at least one of a) the warp component and b) the weft component includes staple spun yarns or filament yarns each made of man-made fibers.   
     
     
         2 . The bedding article according to  claim 1 , wherein the man-made fibers of the staple spun yarns or filament yarns of the second flat woven fabric are either circular cross-section fibers or non-circular cross-section fibers or combination of both. 
     
     
         3 . The bedding article according to  claim 1 , wherein the staple spun yarns for the first flat woven fabric are single end yarns or multi-ply yarns. 
     
     
         4 . The bedding article according to  claim 1 , wherein the staple spun yarns for the first flat woven fabric include only natural fibers and man-made cellulosic fibers. 
     
     
         5 . The bedding article according to  claim 1 , wherein the staple spun yarns for the first flat woven fabric include an intimate blend of natural fibers, man-made cellulosic fibers, and other man-made fibers. 
     
     
         6 . The bedding article according to  claim 1 , wherein the staple spun yarns for the second flat woven fabric are single end spun yarns or multi-ply spun yarns. 
     
     
         7 . The bedding article according to  claim 1 , wherein the filament yarns for the second flat woven fabric are monofilament yarns or multi-filament yarns. 
     
     
         8 . The bedding article according to  claim 1 , wherein a) the warp component and b) the weft component of the second flat fabric includes filament yarns but not staple spun yarns. 
     
     
         9 . The bedding article according to  claim 1 , wherein a) the warp component and b) the weft component of the second flat fabric includes staple spun yarns but not filament yarns. 
     
     
         10 . The bedding article according to  claim 6 , wherein the man-made fibers of the second flat woven fabric are polyester fibers. 
     
     
         11 . The bedding article according to  claim 1 , wherein the drop area is stitched to the top cover with at least one pleat or a gathering effect. 
     
     
         12 . The bedding article according to  claim 1 , further comprising either:
 a. four elastic bands attached to a bottom end of the drop area at corners of the bedding article; or   b. four elastic T-bands attached at the corners of the bedding article.   
     
     
         13 . The bedding article according to  claim 1 , wherein an entirety of a bottom end of the drop area includes an elastic band. 
     
     
         14 . The bedding article according to  claim 1 , wherein the drop area is stitched to an entirety of the perimeter of the top cover with one of the following: an elastic band, a piping, a contrast piping, a cord piping, a flat piping. 
     
     
         15 . The bedding article according to  claim 1 , wherein the drop area includes one of the following:
 a) a hook and loop fastener at one corner of the drop area;   b) a zipper at one corner of the drop area; or   c) a snap fastener at one corner of the drop area.   
     
     
         16 . A method for manufacturing a bedding article, comprising:
 weaving a first flat woven fabric, the first flat woven fabric having a warp component including warp yarns and a weft component including weft yarns interwoven with the warp yarns to define the flat woven fabric, wherein at least one of a) the warp component and b) the weft component comprise a plurality of the staple spun yarns; and   weaving a second flat woven fabric, the second flat woven fabric having a warp component including warp yarns and a weft component including weft yarns interwoven with the warp yarns to define the flat woven fabric, wherein at least one of a) the warp component and b) the weft component includes staple spun yarns or filament yarns each made of man-made fibers;   cutting the first flat woven fabric into a top cover having a perimeter;   cutting the second flat woven fabric into a drop area; and   stitching the drop area to the perimeter of the top cover to form the bedding article.