Abstract:
A coverlet includes a first back layer having edges, a second middle layer having edges and a batting layer having edges and being disposed between and quilted to the first and second layers, A third face layer has edges, covers the second layer and is stitched to the first and second layers and to the batting layer. A binding, preferably between ½ and 1 inch in width, covers all of the edges. The first, second and third layers are all formed of the same fabric, especially a lyocell blend. The batting layer is preferably a lyocell blend and in particular a blend with polyester. A method of producing the coverlet is also provided.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims the priority under 35 U.S.C. 119(e) of U.S. Provisional Patent Application No. 61/320,359, filed Apr. 2, 2010. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The invention relates to a unique type of coverlet and method of producing a coverlet, which maintain the properties of a coverlet, but have the luxury appearance of a duvet. 
         [0004]    2. Description of the Related Art 
         [0005]    U.S. Pat. No. 7,150,055 discloses a multi-layered bedclothes material in which four layers, including a cotton sheeting, a poly or polycotton sheeting, a polyester or polyester acrylic fill and a cotton or polycotton cloth fabric, are shown in  FIG. 7  and quilting is shown in  FIG. 8  thereof. 
         [0006]    U.S. Pat. Nos. 5,925,581 and 5,806,154 respectively disclose a textile laminate and a method of making a textile laminate, in which a quilted fabric  37  shown in  FIG. 6  is made up of several layers, including an outer layer of quilt, a face layer, second fibers of polypropylene, a fiber fill web substrate and an outer layer of quilt, are shown in  FIG. 5 . 
         [0007]    U.S. Pat. No. 3,801,420 shows a plastic quilted bedspread having a sandwich of a top vinyl layer, a padding layer of Dacron or urethane foam and a third interfacing layer, as well as a bottom layer of nylon, with a binding or beading at the edges. The binding or beading at the edges has a simple C-shaped cross-section. 
         [0008]    The prior art products described above use different materials for the layers thereof in order to use less expensive fabrics in regions not seen by the user as well as single-rolled bindings. However, that leads to different shrinkages upon washing and drying, thus degrading long-term performance, especially when washed and dried for industrial uses. They also do not provide a binding which is double-rolled or folded back on itself. 
       BRIEF SUMMARY OF THE INVENTION 
       [0009]    It is accordingly an object of the invention to provide a coverlet and a method of producing a coverlet, which overcome the hereinafore-mentioned disadvantages of the heretofore-known products and methods of this general type and in which the coverlet has a durability and life span suitable for institutional uses, a binding which is double-rolled or folded back on itself and a lyocell blend batting. 
         [0010]    With the foregoing and other objects in view there is provided, in accordance with the invention, a coverlet, comprising a first back layer having edges, a second middle layer having edges and a batting layer having edges and being disposed between and quilted to the first and second layers. A third face layer has edges, covers the second layer and is stitched to the first and second layers and to the batting layer. A binding covers all of the edges. The first, second and third layers are all formed of the same fabric. 
         [0011]    With the objects of the invention in view, there is also provided a method of producing a coverlet. The method comprises providing a first back layer, a second middle layer and a third face layer of the same fabric having edges. A batting layer having edges is placed between the first and second layers. The first layer, the second layer and the batting layer are quilted together. The second layer is covered with the third layer. The third layer is stitched to the first and second layers and to the batting layer. All of the edges are covered with a binding. 
         [0012]    The coverlet produced according to the invention has a durability and life span suitable for institutional uses. 
         [0013]    In accordance with another feature of the invention, the first, second and third layers are all formed of a lyocell blend fabric. This permits the layers of the invention to not only have the advantages of lyocell, but to shrink equally when washed and dried, even under harsh industrial use conditions. 
         [0014]    In accordance with a further feature of the invention, the binding is approximately 2½ inches wide and is folded back on itself or double-rolled leaving a width of approximately ½ inch above the first layer and below the third layer and is stitched to the first, second and third layers and to the batting layer. The binding may have a width of approximately ½ to 1 inch above the first layer and below the third layer and be stitched to the first, second and third layers and to the batting layer. A binding of this width has never before been possible when using a lyocell blend binding or a 100% lyocell binding, because of the difficulty of working with such a fabric. 
         [0015]    In accordance with an added feature of the invention, the batting layer is a lyocell blend, such as polyester and lyocell, and may weigh from 2 to 8 ounces per square yard. Lyocell provides particular advantages as a batting, especially as a blend with polyester, as will be explained below. 
         [0016]    In accordance with an additional feature of the invention, edge stitching is disposed all along the edges of the first, second and third layers, the batting layer and the binding. The edge stitching may have between 8 and 12 stitches to the inch. Thus, the third layer is held in place by the edge stitching and not by quilting. 
         [0017]    In accordance with a concomitant feature of the invention, the binding is stitched to the first, second and third layers and to the batting layer with between 10 and 15 stitches to the inch. 
         [0018]    Thus, the coverlet according to the invention is formed of three layers of fabric and a batting or filling that is quilted, stitched and attached with a binding on all four sides. 
         [0019]    Traditional coverlets include two fabrics and a batting that are quilted and stitched together. There is no binding and no third layer of fabric. 
         [0020]    The process steps for making the coverlet according to the invention can be roughly divided into two separate process streams: 
         [0000]    The process stream for creating the fiber fill used to stuff the coverlet according to the invention.
 
The process stream for the assembly of the coverlet according to the invention, which includes:
 
Cutting and sewing of the fabric to create a shell.
 
Filling the shell with the afore-mentioned fiber fill.
 
Quilting the filled shell to hold the fiber in place in the final product.
 
Closing and finishing the product to create the completed coverlet according to the invention.
 
Packing and shipping the coverlet according to the invention.
 
         [0021]    The diagram of the process shown in  FIG. 5  is used to create fiber fill for the coverlet according to the invention. 
         [0022]    This process mixes precise percentages of a variety of staple polyester, recycled polyester fiber and lyocell fibers along with low-melt binder fibers. 
         [0023]    This fiber mix goes through a series of hoppers, blenders and openers in order to open up and thoroughly mix the various fiber types so they are evenly distributed into a fiber blend. 
         [0024]    At that point, the loose fiber blend goes into the garneting machine, first through a card hopper, then a shaker shoot, then a feed table and finally through the garneting card itself which substantially combs and aligns the fiber creating a web. This web is then double-lapped to create a double web. 
         [0025]    This double web is further lapped to create a batting which is conveyed through an oven with temperature and dwell-time precisely set to allow the inder fibers to melt into the other fibers and form a roll of cohesive fiber fill that balances structural integrity and softness. 
         [0026]    When the roll reaches a maximum workable diameter, corresponding to a length of between 40 to 60 yards, the fiber fill is cut by using a non-heated blade. The use of a non-heated blade as opposed to a hot-wire is required due to the combustible nature of the cellulosic fiber used in this particular blend. 
         [0027]    Other features which are considered as characteristic for the invention are set forth in the appended claims. 
         [0028]    Although the invention is illustrated and described herein as embodied in a coverlet and a method of producing a coverlet, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims. 
         [0029]    The construction of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of the specific embodiment when read in connection with the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING 
         [0030]      FIG. 1  is a diagrammatic, bottom-plan view of a coverlet according to the invention showing a first layer of quilted fabric; 
           [0031]      FIG. 2  is a top-plan view of a coverlet according to the invention showing a third layer or face fabric; 
           [0032]      FIG. 3  is a fragmentary, enlarged, cross-sectional view of the coverlet according to the invention, which is taken along a line  3 - 3  of  FIG. 1 , in the direction of the arrows and shows all of the layers thereof; 
           [0033]      FIG. 4  is a fragmentary, perspective view of a corner of the coverlet according to the invention showing all of the layers thereof; and 
           [0034]      FIG. 5  is a diagram showing the process used to create fiber fill for the coverlet according to the invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0035]    Referring now to the figures of the drawing in detail and first, particularly, to  FIGS. 1 and 2  thereof, there is seen a first layer of fabric  1  forming a bottom of the coverlet and a third layer of fabric  3  forming a top of the coverlet, according to the invention. 
         [0036]    In order to assemble the coverlet, fabric is supplied on non-illustrated rolls that are generally between 90 and 120 inches wide and between 100 and 300 yards long. The coverlet according to the invention is made in the following order. A first layer of fabric  1  is placed on a non-illustrated quilting machine. This layer  1  is known as a “back fabric” as it will be the back of the finished coverlet according to the invention. A batting  10  shown in  FIG. 3  is placed on the back fabric  1 . A second layer of fabric  2  is placed on the batting  10 , effectively making a sandwich of the batting  10  between the two fabrics  1 ,  2 . This second layer  2  is referred to as a “middle fabric” as it will be the middle of the finished coverlet according to the invention. It is noted that the two fabrics  1 ,  2  and the batting  10  are cut evenly so they are all the same size. The two fabrics  1 ,  2  are quilted along stitching  11  with the batting  10  between them. They are quilted fully to the edges of the fabrics  1 ,  2 . 
         [0037]    Once the quilting is complete, the quilted piece  1 ,  2 ,  10  (it is now considered a single piece) is moved to a table where a third layer of fabric  3  is placed on top of the piece  1 ,  2 ,  10 . This third fabric  3  is referred to as a “face fabric” as it will end up being the face of the coverlet according to the invention. It is noted that this third layer  3  is the same size as the quilted piece  1 ,  2 ,  10  it is laying on. The third layer (“face fabric”) is stitched at a sewing station to the quilted piece by edge stitching  12 . It is stitched on all 4 sides using between 8 and 12 stitches per inch. The three layers of fabric  1 ,  2 ,  3  and the batting  10  are now considered one piece. 
         [0038]    The edges of the three layers  1 ,  12 ,  3  are sewn together using a special ½ inch binding  15 . A 2½ inch strip of the face fabric is bias cut (a diagonal cut of fabric that allows the binding to smoothly be sewn around the rounded edges with limited puckering) to form the binding  15 . Lengthwise edges  16  of the binding  15  are rolled inside itself so that no raw edges are exposed in order to prevent fraying. A ½ inch of the binding  15  remains on top and on the bottom of the coverlet according to the invention. 
         [0039]      FIG. 4  shows a corner of the coverlet according to the invention, in which the first, second and third layers  1 ,  2 ,  3  as well as the batting layer  10  are shown. The quilted stitching  11  is also shown, but the edge stitching  12  has been omitted to show the layers in a partially separated condition. 
         [0040]    A final inspection is performed, any lint or debris found is blown off with a pneumatic hose, spots are cleaned off and second quality units are segregated into a separate area. Each unit is packed in polyurethane bag and a size label is affixed to the back of bag in a lower right hand corner. Then four to six units are packed into a carton and each carton is properly labeled with a carton and a case label, assembled into an order and shipped. 
         [0041]    One unique aspect of the coverlet according to the invention is that all three fabrics  1 ,  2 ,  3  being used are of the same construction and content. Although the “middle fabric”  2  is not in plain view and an inexpensive substitute would therefore provide substantial savings, the coverlet according to the invention does not follow that less expensive course. That is because hotels and institutional uses have strict washing and drying requirements. Industrial washing machines are used, and those are neither gentle nor easy on a product during the laundering process. Using a “middle fabric”  2  that is the same content and construction gives strength to the product. 
         [0042]    Fabrics also shrink in machine washing and drying. Having “the middle” fabric  2  shrink at the same exact rate as the face fabric  3  and the back fabric  1  is vital to ensure longterm performance, and this can only be possible with having the same construction and content for all three layers of fabric  1 ,  2 ,  3 . 
         [0043]    The fabrics that form the coverlet according to the invention are made up of various textiles that include but are not limited to: 
       100% Cotton 
     100% Polyester 
       [0044]    100% recycled polyester
 
Polyester and cotton blend
 
Cotton and Lyocell blend
 
Polyester and lyocell blend
 
Cotton, polyester, and lyocell blend
 
         [0045]    Lyocell is a generic fiber name and is defined by the FTC as: 
         [0000]    A cellulose fiber obtained by an organic solvent spinning process where:
 
1)“Organic solvent” means a mixture of organic chemicals and water, and
 
2)“solvent spinning” means dissolving and spinning without the formation of a derivative.
 
         [0046]    The batting  10  that is inside of the coverlet according to the invention ranges from 2 ounces to 8 ounces per square yard. 
         [0047]    A second unique aspect of the coverlet according to the invention is that the batting  10  is a blend of lyocell and polyester fibers. There are no three-layer products existing with a lyocell blend batting. The batting contents range from, but are not limited to: 
         [0000]    100% polyester
 
100% recycled polyester
 
30% lyocell fiber and 70% polyester
 
30% lyocell fiber and 70% recycled polyester
 
A range of 20%-50% lyocell mixed with 50%-80% polyester or recycled polyester
 
         [0048]    The third and most unique aspect of the coverlet according to the invention is the ½ inch binding  15  that is on all four sides. Creating and executing a ½ inch binding is difficult as there is very little fabric making up the binding and holding the product together. The binding  15  must be double rolled and stitched with a minimum of 10 stitches per inch. The binding  15  can range in size from ½ inch to 1 inch and the stitches can range from 10 to 15 per inch. 
         [0049]    The corporate assignee of the instant application, Valley Forge Fabrics, is producing coverlets according to the invention for multiple sales avenues including, but not limited to, hotel beds, institutional beds, and residential beds. Valley Forge Fabrics is using various constructions, designs, colors and patterns on the coverlets according to the invention. 
         [0050]    Valley Forge Fabrics supplies bedding products to the hospitality and lodging industry and there are certain requirements of the coverlet according to the invention apart from technical testing: 
         [0000]    The batting cannot clump after continuous launderings.
 
The batting cannot shift in laundering and use.
 
The face and back fabrics must keep a well kept appearance.
 
The weight of the batting must be consistent throughout the coverlet.
 
The weight of the batting must be consistent from coverlet to coverlet on separate orders.
 
         [0051]    There are certain ASTM requirements that bedding in hotels, lodging, and institutions is required to meet: 
         [0000]    ASTM D4034 Seam Slippage Test—ACT standards call for a minimum of 25 pounds in warp and weft, Valley Forge Fabrics has a self-imposed minimum of 35 pounds in warp and weft for this test.
 
ASTM D2261 Tongue Tear Test—Minimum of 8 pounds.
 
ASTM D5034 Tensile Strength/Breaking strength test—Minimum 35 pounds.
 
FR code of California bulletin  117  must be met or exceeded.
 
ASTM D5362 Bean Bag Snag test must be met or exceeded.
 
AATCC 8 Wet/Dry Crocking—The product must meet or exceed a 4.0 for dry and a 3.5 rating for wet crocking.
 
ASTM D3512 Random Tumble Pill test—Fabrics on a coverlet according to the invention must meet or exceed a rating of 4.0.
 
AATCC 96-2004 Dimensional Changes in laundering—Products must have less than 3% shrinking after 3 launderings.