Bedding systems and methods

Abstract

Inventions of the present disclosure may be considered a bedding characterized by enhanced comfort, durability, long life, and decreased cost. The bedding may include sheeting, which may include pillowcases, pillow shams, a top sheet, a fitted sheet, blankets, and/or a duvet cover, and/or any combination thereof. The sheeting may include a unique weave pattern, which includes various techniques such as plain, dobby, Jacquard, percale, twill, oxford, drill, satin, and/or sateen. The fabric composition may be 100% polyester. A blend of a polyester and micro-polyester warp yarns may be included. Inventions may include a woven bedding fabric, a method for weaving a bedding fabric, and/or a system for a bedding fabric. The woven bedding fabric may be 100% polyester and have a different woven top pattern and bottom pattern. This combination of materials/weaving techniques results in bedding that is not only comfortable and aesthetically pleasing but also durable and cost-effective.

What is claimed is: 
     
         1 . A woven bedding fabric comprising:
 a polyester at least semi dull separable weft yarn having a denier between 10 and 30,   a polyester warp yarn having a denier between 70 and 90,   wherein the weft yarn and the warp yarn are woven to form a 100 percent polyester bedding fabric.   
     
     
         2 . The woven bedding fabric of  claim 1  including a weave pattern, the weave pattern comprising at least one of solid and yarn-dyed woven in a weave technique selected from a group consisting of plain, dobby, Jacquard, percale, twill with a 2×1 pattern, twill with a 2×2 pattern, oxford, drill, satin, sateen, satin with a 4-to-1 float, and satin with a 5-to-1 float. 
     
     
         3 . The woven bedding fabric of  claim 1  wherein the weft yarn is a full dull separable yarn including 12 to 14 filaments. 
     
     
         4 . The woven bedding fabric of  claim 3  wherein the warp yarn and the weft yarn are both a full dull yarn. 
     
     
         5 . The woven bedding fabric of  claim 4  wherein the warp yarn is a cooling yarn. 
     
     
         6 . The woven bedding fabric of  claim 5  including a first face and a second face, wherein the first face is a different weave pattern than the second face. 
     
     
         7 . The woven bedding fabric of  claim 6  wherein the first face is a satin woven face. 
     
     
         8 . The woven bedding fabric of  claim 7  wherein the second face is a percale woven face. 
     
     
         9 . The woven bedding fabric of  claim 1  wherein the percale woven face is a top surface and the sateen woven face is a bottom surface. 
     
     
         10 . The woven bedding fabric of  claim 1  including an application of a polymeric softener to the woven bedding fabric during construction. 
     
     
         11 . The woven bedding fabric of  claim 10  wherein the bedding fabric is an anti-static fabric, anti-bacterial fabric, and/or an anti-wrinkle fabric. 
     
     
         12 . The woven bedding fabric of  claim 1  wherein the polyester weft separable yarn includes 12 to 14 filaments. 
     
     
         13 . The woven bedding fabric of  claim 1  wherein the bedding fabric includes 10 yarns of 20 denier polyester weft separable yarn in the weft. 
     
     
         14 . The woven bedding fabric of  claim 12  wherein the fabric is constructed on a water jet loom. 
     
     
         15 . The woven bedding fabric of  claim 14  wherein the weft yarns are parallel inserted weft yarns. 
     
     
         16 . The woven bedding fabric of  claim 1  including an oil percentage in the warp yarn of 2.5% or higher. 
     
     
         17 . The woven bedding fabric of  claim 1  constructed with a loom speed of less than 600 RPM. 
     
     
         18 . The woven bedding fabric of  claim 1  including an oil application percentage of 2.5% or higher and a loom construction speed of less than 600 RPM. 
     
     
         19 . The woven bedding fabric of  claim 1  including an oil application percentage between 3.0% and 3.5% and a loom construction speed of less than 550 RPM. 
     
     
         20 . The woven bedding fabric of  claim 19  including an anti-static chemical applied at an initial dyeing stage. 
     
     
         21 . The woven bedding fabric of  claim 1  wherein bedding includes a pillowcase, a pillow wham, a top sheet, a fitted sheet, a cover, a duvet, a duvet cover, a blanket, and any combination thereof. 
     
     
         22 . A method for weaving a bedding fabric comprising:
 inserting a polyester weft separable full dull yarn having a denier between 8 and 30,   inserting a polyester warp full dull yarn having a denier between 50 and 150,   forming bedding fabric including a thread count greater than 200,   applying an oil percentage of at least 3 percent,   maintaining a loom construction speed of 500 RPM or less.   
     
     
         23 . The method of  claim 22  including forming a percale fabric side and a satin fabric side. 
     
     
         24 . A system for a bedding fabric comprising:
 a bedding item for covering a bed surface including:
 a polyester at least semi dull weft separable yarn having a denier between 10 and 30, 
 a polyester warp at least semi dull yarn having a denier between 70 and 90, 
 a thread count of at least 300, 
   the bedding article formed on a water jet loom and including:
 an oil application percentage of at least 3 percent, and 
 a loom construction speed of 550 RPM or less. 
   
     
     
         25 . A woven bedding fabric having cotton characteristics, but not including cotton, comprising:
 the fabric including a set of at least semi dull warp yarns and a set of at least semi dull weft yarns,   said warp yarns being polyester and forming a first fabric surface,   said weft yarns being polyester and forming an opposite fabric surface,   wherein said first fabric surface and said second fabric surface are different weave patterns,   said weave pattern characterized by:
 a percale face formed by a first and seventh shaft percale 1/1, and 
 a satin face formed by a second through sixth shaft satin 4/1. 
   
     
     
         26 . The woven bedding fabric of  claim 25  including:
 an application of at least a 3% oil, and 
 an application of a loom speed of less than 550 RPM. 
 
     
     
         27 . A method for weaving a polyester bedding fabric on a water jet loom, comprising:
 inserting an 70D to 80D polyester cooling yarn in the warp on the loom,   directing a pressurized water jet to create a shed in the warp yarn,   propelling a 10D to 20D separable full dull polyester weft yarn through the shed using the water jet,   applying tension to the weft yarn to secure it within the warp,   wherein the water jet is controlled to an RPM of 550 or less and an oil percentage of at least 3.5% is applied to minimize a yarn breakage.