EXHIBIT 2

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11 1111111 111 111111 11111 1111111 11111111 111111 11111111 11 111111 111111ll Dl ll US0091 3 1790B2 

(12) United States Patent 

Agarwal 

(10) Patent No.: US 9,131,790 B2 

(45) Date of Patent: Sep. 15, 2015 

(54) PROLIFERATED THREAD COUNT OF A 

WOVEN TEXTILE BY SIMULTANEOUS 

INSERTION WITHIN A SINGLE PICK 

INSERTION EVENT OF A LOOM APPARATUS 

MULTIPLE ADJACENT PARALLEL YARNS 

DRAWN FROM A MULTI-PICK YARN 

PACKAGE 

(71) 

(72) 

(73) 

(*) 

(21) 

(22) 

(65) 

(60) 

(51) 

Applicant: Arun Agarwal, Dallas, TX (US) 

Inventor: Arun Agarwal, Dallas, TX (US) 

Assignee: AAVN, INC., Dallas, TX (US) 

Notice: Subject to any disclaimer, the term of this 

patent is extended or adjusted under 35 

U.S.C. 154(b) by 0 days. 

Appl. No.: 14/185,942 

Filed: Feb. 21, 2014 

Prior Publication Data 

US 2015/0047736A1 Feb. 19, 2015 

Related U.S. Application Data 

Provisional application No. 61/866,047, filed on Aug. 

15, 2013. 

Int. Cl. 

DO3D 1/00 

A47G 9/02 

(2006.01) 

(2006.01) 

(Continued) 

(52) U.S. Cl. 

CPC A47G9/0238 (2013.01); D03D 1/00 

(2013.01); DO3D 1/0017(2013.01); 

(Continued) 

(58) Field of Classification Search 

CPC DO3D 15/00; DO3D 25/00; DO3D 1/00; 

A47G 9/02; A45F 5/00; A45F 2005/008; 

A45F 2005/006; .A45F 2200/0575; A45F 5/02; 

A45F 5/004; A45F 5/021; A45F 2003/006; 

SINGLE 

IICI 

INSERTION 

EVENT 

401

416f I 

L 

416 

L. c 14410 ZOO 

PARALLEL YARN 

BINAFYYAFNE 122 

401 

122 

122 

122 122 

DIAGRAMVIEW 

I 

.A45F 3/14; A63C 11/222; A45C 13/20; 

A45C 13/30; A45B 2009/025; A411) 19/0048; 

A44C 5/0007; A44C 5/0038; A44C 5/0053; 

A621335/0031; B25B 23/00; Y1OS 224/904; 

Y1OS 224/914 

See application file for complete search history. 

(56) References Cited 

CA 

CA 

U.S. PATENT DOCUMENTS 

1,334.901 A 

2,505,027 A 

3/1920 Higdon 

7/1946 Belsky 

(Continued) 

FOREIGN PATENT DOCUMENTS 

2155880 Al 2/1997 

2346947 At 5/2000 

(Continued) 

OTHER PUBLICATIONS 

"Woven Fabrics and Ultraviolet Protection", University of Maribor, 

Faculty of Mechanical Engineering, Slovenia on Aug. 18, 2010 by 

Polona Dobnik Dubrovski (pp. 25) http://cdn.intechopen.com/pdfswm/l225l.pdf. 

(Continued) 

Primary Examiner BobbyMuromoto, Jr. 

(74) Attorney, Agent, or Firm Raj Abhyanker, P.C. 

(57) ABSTRACT 

The proliferation of the thread count of a woven textile is 

accomplished through simultaneous insertion, within a single 

pick insertion event of a loom apparatus, of multiple adjacent 

parallel yams drawn from a multi-pick yarn package. In one 

or more embodiments, multiple texturized polyester weft 

yarns of denier between 15 and 50 are wound on a single 

bobbin in a parallel adjacent fashion such that they may be fed 

into an air jet pick insertion apparatus of an air jet loom to 

weave a textile that has between 90 to 235 ends per inch 

cotton warp yams and between 100 and 765 polyester weft 

yarns. 

WEFT DIRE TION 

p N 

p 

401 

VA 

19 Claims, 6 Drawing Sheets 

WARP YARNS 

426 

WEFT UNDER 

SW 

wErTOVER 

WARP 

604 

WARP 

-DIRECT ON 

WOVEN FABRIC 

NT2F,AFING DIAGRAM 

22 

426 122 

Confidential AQ-HawesVMacys_00 16026 

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US 9,131,790 B2 

Page 2 

(51) lnt.CI. 

D03D 13/00 (2006.01) 

D03D 47/30 (2006.01) 

D03D 23/00 (2006.01) 

(52) U.S. Cl. 

CPC D03D 13/004 (2013.01); D03D 13/008 

(2013.01); D03D 47/30 (2013.01); D03D 

47/3046(2013.01); DIOB 2201/02 (2013.01); 

DIOB 2331/04 (2013.01); DIOB 2501/00 

(2013.01); DIOB 2503/06 (2013.01) 

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7,143,790 B2 12/2006 Liao 

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7,325,263 B2 2/2008 Stribling 

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8,334.524 B2 12/2012 

8,566,983 B2 10/2013 

8,624,212 B2 1/2014 

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8,640,282 B2 2/2014 

8,689,375 B2 4/2014 

8,690,964 B2 4/2014 

8,707,482 B! 4/2014 

8,911,833 B2 12/2014 

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Chamberlain 

Seago et al. 

Kahn 

Fogel 

Dordevic 

Gronbach 

Schnegg 

Kasai et al. 

Seago 

Vaughn 

West etal. 

Karde!! etal. 

Whitley 

Flint etal. 

Hughes 

Mohamed s 

Collier 

Hudson 

Heiman 

428/141 

tal. 

442/214 

139/420 A 

Rabin et al. 

Demeo et al. 

Monaco 

Yang etal. 

Rowson et al. 

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Stinchcomb 

Kramer etal. 

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Medoff 

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Fair 

Covelhi 

Lovingood 

139/391 

Confidential AQ-HawesVMacys_OO 16027 

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US 9,131,790 B2 

Page 3 

(56) References Cited 

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2004/0040090 Al 3/2004 Woollen 

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FOREIGN PATENT DOCUMENTS 

CN 1361315 A 7/2002 

CN 101385091 A 3/2009 

CN 202072865 U 12/2011 

CN 203475074 U 3/2014 

CN 103820902 A 5/2014 

EP 0758692 Al 2/1997 

EP 0913518 Al 5/1999 

EP 1389645 A2 2/2004 

EP 1678358 Al 7/2006 

EP 1400616 Bl 2/2007 

WO 02059407 Al 8/2002 

WO 2005045111 Al 5/2005 

WO 2006062495 Al 6/2006 

WO 2006069007 A2 6/2006 

WO 2007133177 A2 11/2007 

WO 2008042082 A2 4/2008 

WO 2009115622 Al 9/2009 

OTHER PUBLICATIONS 

"Electromagnetic Shielding Fabrics", LessEMF.com website on Jul. 

8, 2015 (pp. 19) http://www.lessemf.comlfabric.htrnl. 

"Ultraviolet (UV) Protection of Textiles: A Review", International 

Scientific Conference, Gabrovo on Nov. 19-20,2010 by Mine Akgun 

et al. (pp. 11) http://www.singipedia.com/attachinent.php?attachmentid=1907&d=1296035072. 

"Textiles in Electromagnetic Radiation Protection", Journal of Safety 

Engineering, p-ISSN: 2325-0003 in 2013 by Subhankar Maity et al. 

(pp. 9) http://www.sapub.org/g!obal/showpaperpdf,aspx?doi=10. 

5923/j .safety.20 130202.01. 

"TV Protection Textile Materials", AUTEX Research Journal, vol. 7, 

No.1 in Mar. 2007 byD. Saravanan(pp. 10) http://www.autexrj.com/ 

cms/za!aczonep!iki/6-07-1 .pdf. 

* cited by examiner 

Confidential AQ-HawesVMacys_OO 16028 

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U.S. Patent 

SUPPLY 

PACKAGE 102 

103 

Sep. 15, 2015 Sheet 1 of 6 

PRIMARY 

INPUT 

ROLLER 

106 

PARTIALLY ORIENTED 

102 POLYESTER YARN (POY) 

103 

MULTI-PICK 

YARN PACKAGE 

100 

TRAVERSE GUIDE 

126 

ADJACENT 

PARALLEL YARNS 

101 

WIPER GUIDE 

124 

122 

TEXTURIZED YARN 

122 

ORIENTED 

POLYESTER YARN 

104 

106 

104 

108 

COOLING PLATE 

110 

INTERMINGLING JET 

115 

20 

OIL APPLICATOR 

120 

118 

FIGURE 1 

US 9,131,790 B2 

SECONDARY INPUT 

ROLLER 107 

107 

PRIMARY 

HEATER 

108 

110 

FRICTION 

TWISTING 

UNIT 112 

INTERMEDIATE 

ROLLER 

114 

115 

SECONDARY 

HEATER 

' 116 

OUTPUT 

ROLLER 

118 

MULTI-PICK YARN PACKAGE 

CONSTRUCTION VIEW 

150 

Confidential AQ-HawesVMacys_OO 16029 

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U.S. Patent Sep. 15, 2015 Sheet 2 of 6 US 9,131,790 B2 

START ) 

ç200 

SUPPLY MULTIPLE PARTIALLY ORIENTED POLYESTER YARNS FROM MULTIPLE SUPPLY 

PACKAGES TO INPUT ROLLERS TO GENERATE MULTIPLE ORIENTED POLYESTER YARNS 

HEAT MULTIPLE ORIENTED POLYESTER YARNS WITH PRIMARY HEATERS 

20 r 

V 

COOL THE MULTIPLE ORIENTED POLYESTER YARNS WITH COOLING PLATES 

20 r 

TWIST THE MULTIPLE ORIENTED POLYESTER YARNS WITH FRICTION TWISTING UNITS 

V 

ç206 

208 

COLLECT THE MULTIPLE ORIENTED POLYESTER YARNS WITH INTERMEDIATE ROLLERS 

V 

21 r 

INTERMINGLE THE FILAMENTS OF THE MULTIPLE ORIENTED POLYESTER YARNS WITH A 

UNIFORM PRESSURE OF AIR WITH INTERMINGLING JETS TO PROVIDE LOWER STABILITY 

INTERLACING AND HELP BIND FILAMENTS WITHIN EACH OF THE ORIENTED POLYESTER 

YARNS 

V 

HEAT THE MULTIPLE ORIENTED POLYESTER YARN WITH SECONDARY HEATERS 

V 

21 r 

r 21 

APPLY AN CONNING OIL TO THE MULTIPLE ORIENTED POLYESTER YARNS WITH OIL 

APPLICATORS 

r 21 

WIND THE MULTIPLE ORIENTED POLYESTER YARN TOGETHER ONTO ONE BOBBIN AT A 65-70 

TYPE A SHORE HARDNESS THROUGH THE USE OF A WIPER GUIDE AND TRAVERSE GUIDE 

TO FORM A MULTI-PICK YARN PACKAGE 

FIGURE 2 

Confidential AQ-HawesVMaCys_OO 16030 

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U.S. Patent Sep. 15, 2015 Sheet 3 of 6 US 9,131,790 B2 

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U.S. Patent Sep. 15, 2015 Sheet 6 of 6 US 9,131,790 B2 

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Confidential AQ-HawesVMacys_00 16034 

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US 9,131,790 B2 

1 

PROLIFERATED THREAD COUNT OF A 

WOVEN TEXTILE BY SIMULTANEOUS 

INSERTION WITHIN A SINGLE PICK 

INSERTION EVENT OF A LOOM APPARATUS 

MULTIPLE ADJACENT PARALLEL YARNS 

DRAWN FROM A MULTI-PICK YARN 

PACKAGE 

CLAIMS OF PRIORITY 

This patent application claims priority from, and hereby 

incorporates by reference and claims priority from the 

entirety of the disclosures of the following cases and each of 

the cases on which they depend and further claim priority or 

incorporate by reference: U.S. Provisional patent application 

No. 61/866,047, titled 'IMPROVED PROCESS FOR MAKING TEXTIJRIZEDYARNANI) FABRIC FROM POI LYESTER AND COMPOSITION THEREOF' filed on Aug. 15, 

2013. 

FIELD OF TECHNOLOGY 

This disclosure relates generally to textiles and, more particularly, to a method, a device and/or a system of a proliferated thread count of a woven textile by simultaneous insertion 

within a single pick insertion event of a loom apparatus multiple adjacent parallel yams drawn from a multi-pick yarn 

package. 

BACKGROUND 

A consumer textile, for example apparel or bed sheets, may 

possess several characteristics that make it desirable. One 

desirable characteristic may be comfort for fabrics that come 

in contact with human skin. Another desirable characteristic 

may be durability, as consumer textiles may be laundered in 

machine washers and dryers that may tend to shorten the 

useful lifespan of the textile. In commercial operations, 

machine laundering may occur more than in residential or 

small-scale settings, which may further shorten the lifespan 

of the textile. 

For textiles that contact human skin (for example T-shirts, 

underwear, bed sheets, towels, pillowcases), one method to 

increase comfort may be to use cotton yams. Cotton may have 

high absorbency and breathability. Cotton may also generally 

be known to have a good "feel" to consumers. 

But cotton may not be robust when placed in an environment with heavy machine laundering. To increase durability 

while retaining the feel and absorbency of cotton, the cotton 

yarns may he woven in combination with synthetic fibers 

such as polyester. Cotton may be used as warp yams, while 

synthetic yams may be used as weft yarns. 

Constructing the textile using yams with a smaller denier 

may also increase comfort. Using these relatively fine yams 

may yield a higher "thread count." A thread count of a textile 

may be calculated by counting the total weft yarns and warp 

yarns in along two adjacent edges of a square of fabric that is 

one-inch by one-inch. The thread count may be a commonly 

recognized indication of the quality of the textile, and the 

thread count may also be a measure that consumers associate 

with tactile satisfaction and opulence. 

However, fine synthetic weft yams, such as polyester, may 

break when fed into a loom apparatus. Cotton-polyester 

hybrid weaves may therefore be limited to larger denier synthetic yams that the loom may effectively use. Thus, the 

thread count, and its associated comfort and luxury, may be 

limited. 

2 

In an attempt to claim high thread counts, some textile 

manufacturers may twist two yams together, such that they 

may be substantially associated, before using them as a single 

yarn in a weaving process. A twisted yarn may yield proper5 ties in the textile similar to the use of a large denier yam. 

Manufactures of textiles with twisted yarns may include 

within the advertised "thread count" each strand within each 

twisted yarn, even though the textile may not feel of satisfactory quality once it has been removed from its packaging and 

10 handled by the consumer. The Federal Trade Commission has 

taken the position in an opinion letter that it considers the 

practice of including each yam within a twisted yarn in the 

thread count as deceptive to consumers. 

Because fine denier yarns may break in a loom apparatus, 

15 cotton-synthetic blends may be limited to low thread counts 

and thus relatively low quality and comfort. 

SUMMARY 

20 Disclosed are a method, a device and/or a system of proliferated thread count of a proliferated thread count of a 

woven textile by simultaneous insertion within a single pick 

insertion event of a loom apparatus multiple adjacent parallel 

yarns drawn from a multi-pick yarn package. 

25 In one embodiment, a woven textile fabric includes from 

90 to 235 ends per inch warp yams and from 100 to 765 picks 

per inch multi-filament polyester weft yams. The warp yarns 

may be made of a cotton material, and may have a total thread 

count is from 300 to 1000. The woven textile fabric may be 

30 made of multi-filament polyester yams having a denier of 20 

to 65. The woven textile fabric may have multi-filament polyester yams having a denier of 15 to 35. The woven textile 

fabric may also have multi-filament polyester yams have a 

denier of 20 to 25. 

35 Additionally, the multi-filament polyester yams may contain 10 to 30 filaments each. The woven textile fabric may 

have a minimum tensile strength in a warp direction of 17 

kilograms to 65 kilograms and a minimum tensile strength in 

a weft direction of 11.5 kilograms to 100 kilograms. The 

40 woven textile fabric may have a warp-to-fill ratio that is 

between 1:2 to 1:4. 

In another aspect, a method of weaving a fabric includes 

drawing multiple polyester weft yarns from a weft source to 

a pick insertion apparatus of a loom apparatus. The method 

45 also includes conveying by the pick insertion apparatus the 

multiple polyester weft yarns across a warp shed of the loom 

apparatus through a set of warp yarns in a single pick insertion 

event of the pick insertion apparatus of the loom apparatus 

and beating the multiple polyester weft yams into a fell of the 

50 fabric with a reed apparatus of the loom apparatus such that 

the set of warp yams and/or the multiple polyester weft yarns 

become interlaced into a woven textile fabric. The method 

forms the woven textile having from 90 to 235 ends per inch 

warp yams and from 100 to 765 picks per inch multi-filament 

55 polyester weft yams. 

The denier of the polyester weft yarns may be between 15 

and 50. The weft source may be a weft yam package in which 

the multiple polyester weft yarns are wound substantially 

parallel to one another and substantially adjacent to one 

60 another to enable the simultaneous inserting of the multiple 

polyester weft yams during the single pick insertion event of 

the pick insertion apparatus of the loom apparatus. Further, 

the number of the multiple polyester well yarns wound substantially parallel to one another and substantially adjacent to 

65 one another on the weft yam package may be two. The number of the multiple polyester well yams conveyed by the pick 

insertion apparatus across the warp shed of the loom apparaConfidential AQ-HawesVMacys_OO 16035 

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US 9,131,790 B2 

3 

tus through the set of warp yarns in the single pick insertion 

event of the pick insertion apparatus of the loom apparatus 

may be between two and eight. 

Additionally, the pick insertion apparatus of the loom 

apparatus may be an air jet pick insertion apparatus. The 

multiple polyester weft yams may be wound on the yarn 

package at an angle of between 15 and/or 20 degrees to enable 

the simultaneous inserting of the multiple polyester weft 

yarns during the single pick insertion event of the pick insertion apparatus of the loom apparatus. Additionally, the multiple polyester weft yams may be wound on the yarn package 

at a type A shore hardness of between 65 to 70 to enable the 

simultaneous inserting of the multiple polyester weft yams 

during the single pick insertion event of the pick insertion 

apparatus of the loom apparatus. Further, the multiple polyester weft yams may be treated with a conning oil comprising 

a petroleum hydrocarbon, an emulsifier and/or a surfactant to 

enable the simultaneous inserting of the multiple polyester 

weft yarns during the single pick insertion event of the pick 

insertion apparatus of the loom apparatus. The pick insertion 

apparatus of the loom apparatus may be a rapier insertion 

apparatus and/or a bullet insertion apparatus. 

An airflow of a primary nozzle and/or a fixed nozzle of an 

air jet pick insertion apparatus pick insertion apparatus may 

be adjusted to between 12 Nm /hr to 14 Nm /hr to enable the 

simultaneous inserting of the multiple polyester weft yams 

during the single pick insertion event of the pick insertion 

apparatus of the loom apparatus. The airflow of each relay 

nozzle in the air jet pick insertion apparatus pick insertion 

apparatus may be adjusted to between 100 and/or 140 millibars to enable the simultaneous inserting of the multiple 

polyester weft yams during the single pick insertion event of 

the pick insertion apparatus of the loom apparatus. A drive 

time of a drive time of a relay valve of the airjet pick insertion 

apparatus pick insertion apparatus may he adjusted to 

between 90 degrees and/or 135 degrees to enable the simultaneous inserting of the multiple polyester weft yarns during 

the single pick insertion event of the pick insertion apparatus 

of the loom apparatus, and the multiple polyester weft yams 

may have a denier of 22.5 with 14 filaments. 

The multiple polyester weft yams may be treated with a 

primary heater heated to approximately 180 degrees Celsius 

to enable the simultaneous inserting of the multiple polyester 

weft yarns during the single pick insertion event of the pick 

insertion apparatus of the loom apparatus, and the multiple 

polyester weft yam may be treated with a cooling plate at a 

temperature of between 0 and 25 degrees Celsius subsequent 

to the treating with the primary heater. 

In yet another aspect, a bedding material having the combination of the "feel" and absorption characteristics of cotton 

and the durability characteristics of polyester with multifilament polyester weft yarns having a denier of between 15 

and 50 and cotton warp yams woven in a loom apparatus that 

simultaneously inserts multiple of the multi-filament polyester weft yams during a single pick insertion event of the loom 55 

apparatus in a parallel fashion such that each of the multiple 

polyester weft yarns maintain a physical adjacency between 

each other during the single pick insertion event, increasing 

the thread count of a woven fabric of the bedding material 

based on the usage of multi-filament polyester weft yams 

with a denier between 15 and 50. The bedding is a woven 

textile fabric that includes from 90 to 235 ends per inch warp 

yarns and from 100 to 765 picks per inch multi-filament 

polyester weft yams. 

The total thread count of the bedding material may be from 

300 to 1000 and each multi-filament polyester yarn count of 

the bedding material may have from 10 to 30 filaments each. 

4 

The methods and systems disclosed herein may be implemented in any means for achieving various aspects, and may 

be executed in a form of a non-transitory machine-readable 

medium embodying a set of instructions that, when executed 

5 by a machine, cause the machine to perform any of the operations disclosed herein. Other features will be apparent from 

the accompanying drawings and from the detailed description 

that follows. 

10 BRIEF DESCRIPTION OF THE DRAWINGS 

The embodiments of this invention are illustrated by way of 

example and not limitation iii the figures of the accompanying 

drawings, in which like references indicate similar elements 

15 and in which: 

FIG. 1 is a multi-pick yarn package construction view in 

which two discrete partially-oriented polyester yarns are oriented, texturized, convened to convened to parallel adjacency 

by a wiper guide, and then wound onto a single multi-pick 

20 yarn package, according to one or more embodiments. 

FIG. 2 is a process diagram showing the procedure by 

which the partially-oriented polyester yarn may he oriented, 

texturized and wound on a spindle to form the multi-pick yam 

package of FIG. 1, according to one or more embodiments. 

25 FIG. 3 is a multi-pick yam package view showing the 

parallel configuration of the adjacent texturized yarns and 

their crossing wind angle within the multi-pick yarn package, 

imposed by the wiper guide and traverse guide of FIG. 1, 

respectively, according to one or more embodiments. 

30 FIG. 4 is a binary simultaneous weft insertion view of an 

exemplarily use of the multi-pick yam package of FIG. 3 in 

which two adjacent parallel yarns forming a binary pick yam 

package are fed into an air jet loom apparatus such that a 

primary nozzle simultaneously propels two picks across a 

35 warp shed of the loom apparatus in a single pick insertion 

event, according to one or more embodiments. 

FIG. 5 is a quaternary simultaneous weft insertion view of 

an exemplarily use of more than one of the multi-pick yam 

package of FIG. 3 in which two of the binary pick yam 

40 packages of FIG. 4 are fed into an air jet loom apparatus such 

that a primary nozzle simultaneously propels four picks 

across a warp shed of the loom apparatus in a single pick 

insertion event, according to one or more embodiments. 

FIG. 6 is a pseudo-plain weave diagram view and textile 

45 edge view that demonstrates the resulting I x2 weave when 

the adjacent parallel yam pair from the binary pick yam 

package of FIG. 4 is conveyed across the warp shed of a loom 

apparatus configured to interlace warp and weft yarns after a 

single pick insertion event, according to one or more embodi50 ments. 

Other features of the present embodiments will be apparent 

from the accompanying drawings and from the detailed 

description that follows. 

I)ETAIiLEI) DESCRIPTION 

Disclosed area method, a device and a system of a proliferated thread count of a woven textile by simultaneous insertion within a single pick insertion event of a loom apparatus 

60 multiple adjacent parallel yams drawn from a multi-pick yarn 

package. Although the present embodiments have been 

described with reference to specific example embodiments, it 

will be evident that various modifications and changes may be 

made to these embodiments without departing from the 

65 broader spirit and scope of the various embodiments. 

FIG. 1 is a multi-pick yam package construction view in 

which two discrete partially-oriented polyester yarns are oriConfidential AQ-HawesVMacys_OO 16036 

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US 9,131,790 B2 

5 

ented, texturized, convened to convened to parallel adjacency 

by a wiper guide, and then wound onto a single multi-pick 

yarn package, according to one or more embodiments. Particularly, FIG. 1 illustrates a multi-pick yarn package 100, an 

adjacent parallel yams 101, a supply package 102, a partially 

oriented polyester yam (POY) 103, an oriented polyester yarn 

104, an primary input roller 106, a secondary input roller 107, 

a primary heater 108, a cooling plate 110, a friction twisting 

unit 112, an intermediate roller 114, a secondary heater 116, 

an output roller 118, an oil applicator 120, a texturized yarn 

122, a wiper guide 124, and a traverse guide 126. 

In the embodiment of FIG. 1, the multi-pick yam package 

100 may be formed from two of the partially oriented polyester yarns 103 (POY) that may be oriented and texturized by 

a number of elements set forth in FIG. 1. The multi-pick yarn 

package 100 may be used to supply weft yams (weft yams 

may also be known as "fill," "picks," "woof' and/or "filling 

yarns") in any type of loom apparatus, including those with 

pick insertion mechanisms such as rapier, bullet, magnetic 

levitation bullet, water jet and/or air jet. In one preferred 

embodiment, and as described in conjunction with the 

description of FIG. 4 and FIG. 5, the loom may use an air jet 

pick insertion mechanism. The partially oriented polyester 

yarn 103 may be comprised of one or more extruded filaments 

of polyester. 

The primary input roller 106 may draw the partially oriented polyester yarn 103 from the supply package 102. The 

secondary input roller 107, which may operate at a higher 

speed than the primary input roller 106, may then draw the 

partially oriented polyester yam 103 from the primary input 

roller 106, forming the oriented polyester yarn 104. In a 

preferred embodiment, the secondary input roller 107 rotates 

at 1.7 times the speed of the primary input roller 106. 

The oriented polyester yam 104 may then he drawn 

through the primary heater 108. The primary heaters may be 

heated to a temperature between 50° C. and 200° C. In one 

preferred embodiment, the primary heater may be set to 190° 

C. After leaving the heater, the oriented polyester yarn 104 

may then be exposed to the cooling plate 110 that may be set 

at a temperature between 0° C. and room temperature (e.g., 

about 20-25° C.). The cooling plate may also be set at temperatures between 25° C. and 40° C., and in one preferred 

embodiment 38° C. 

The intermediate roller 114 may draw the oriented polyester yarn 104 from the cooling plate 110 to the friction twisting 

unit 112. The friction twisting unit 112 (e.g., an FTU) may 

twist/detwist the filaments within the oriented polyester yarn 

104 such that it gains a texture (e.g., such that the resulting 

textile the oriented polyester yam 104 may be woven into 

gains in "body" or heft) and may also provide a low stability 

interlacing in the weaving process. The friction twisting unit 

112 may also help to intermingle the polyester filaments that 

may comprise the oriented polyester yam 104. The twist 

imparted by the friction twisting unit 112 may be translated 

through the oriented polyester yarn 104 back to the primary 

heater 108, which, in conjunction with the cooling plate 110, 

may "fix" the molecular structure of the twisted filaments of 

the oriented polyester yam 104, imbuing it with a "memory" 

of torsion. 

The intermediate roller 114 may convey the oriented polyester yarn 104 to the intermingling jet 115 that may apply a 

uniform air pressure to the oriented polyester yam 104 to 

provide counter-twist to the friction twisting unit 112. The 

oriented polyester yarn 104 may then be heated by the secondary heater 116. The secondary heater 116 may be set to 

between 50° C. and 200°C. In one preferred embodiment, the 

6 

intermingling jet 115 may be set to a pressure of 2 bars and the 

secondary heater 116 may be set to a temperature of 170° C. 

The output roller 118 may convey the oriented polyester 

yarn 104 to the oil applicator 120.1 he oil applicator 120 may 

S apply conning oil. The conning oil applied by the oil applicator 120 may act as a lubricant, reducing a friction between 

two or more yams (e.g., several of the oriented polyester 

yarns 104) and between one or more yams and a loom apparatus (e.g., metallic components the oriented polyester yam 

10 104 may contact). The conning oil may also minimize a static 

charge formation of synthetic yams. The conning oil may be 

comprised of a mineral oil (e.g., a petroleum hydrocarbon), a 

moisture, an emulsifier (e.g., a non ionic surfactant, a fatty 

alcohol an ethoxylatlate, and/or a fatty acid), and/or a surfacis tant. In addition, as will be shown and described in conjunction with the description of FIG. 4, the conning oil may help 

prevent a dissociation of the adjacent parallel yams 101 when 

the adjacent parallel yams 101 are propelled across a warp 

shed 408 during a single pick insertion event 416 of a loom 

20 apparatus 405. The rate at which the oil applicator 120 applies 

the conning oil may be adjusted to a minimum amount 

required to prevent dissociation of the adjacent parallel yams 

101 during a pick insertion event (e.g., the single pick insertion event 416 of FIG. 4), depending on the type of loom 

25 apparatus employed. 

After conning oil may be applied by the oil applicator 120, 

the oriented polyester yarn 104 may he the texturized yam 

122 ready to be wound on a yam supply package spindle (e.g., 

to become the multi-pick yam package 100). 

30 The wiper guide 124 may collect and convene multiple of 

the texturized yarns 122 such that the texturized yarns 122 

become the adjacent parallel yarns 101. The adjacent parallel 

yarns 101 may then enter the traverse guide 126, which may 

wind the adjacent parallel yarns 101 onto a spool to form the 

35 multi-pick yarn package 100. The traverse guide 126 may 

wind the multi-pick yarn package 100 at a crossing wind 

angle of between 15-20° (e.g., the crossing wind angle 300 of 

FIG. 3, denoted 0), and at a type A shore hardness of between 

65 and 70. In one preferred embodiment, the number of 

40 texturized yams 122 that may be convened by the wiper guide 

124 to be would onto the multi-pick yam package 100 may be 

two (e.g., the binary pick yarn package 400 of FIG. 4). 

In one preferred embodiment, the partially oriented polyester yarn 103 may have a denier of 22.5 with 14 polyester 

45 filaments. In another preferred embodiment, the partially oriented polyester yam 103 may have a denier of between 15 and 

25. One skilled in the art will know that denier may be a unit 

of measure for a linear mass density of a fiber, such measure 

defined as the mass in grams per 9000 meters of the fiber. The 

50 wiper guide 124 may substantially unite the texturized yam 

122 into the adjacent parallel yams 101 such that, if considered a unitary yam, the adjacent parallel yams 101 may have 

28 filaments and a denier of about 45. In contrast, if two ofthe 

partially oriented polyester yarns 103 with 14 filaments and a 

55 denier of 22.5 are twisted around one another, the twisted 

yarns, if considered a unitary yam, may have a denier higher 

than 45 due to increased linear mass density of twisted fibers 

within a given distance. Yarns twisted in this fashion may also 

not qualify as independent yams for calculating thread count 

60 according to industry standards of regulatory bodies. 

FIG. 2 is a process diagram showing the procedure by 

which the partially-oriented polyester yarn may be oriented, 

texturized and wound on a spindle to form the multi-pick yam 

package of FIG. 1, according to one or more embodiments. In 

65 operation 200, multiple partially oriented polyester yarns 

(e.g., the partially oriented polyester yams 103) may be supplied to input rollers to yield oriented yam (e.g., the oriented 

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polyester yam 104). In operation 202, multiple oriented yams 

are heated by two primary heaters. In operation 204, the 

multiple oriented polyester yarns may be cooled by cooling 

plates. In operation 206, the multiple oriented polyester yams 

may be twisted, individually, by friction twisting units. In 

operation 208, the oriented polyester yarns may be collected 

by intermediate rollers. In operation 210, the filaments of the 

oriented polyester yams may be intermingled, individually, 

by a uniform pressure of air by intermingling jets to provide 

lower stability interlacing and help bind the filaments within 

each individual partially oriented polyester yarn 104. 

In operation 212, the multiple of the oriented polyester 

yarns may be heated by secondary heaters, and in operation 

214, the oriented polyester yams may have comling oil 

applied to each yarn by oil applicators. In operation 216, the 

oriented polyester yarns (which may now be the texturized 

yarns 122), may be wound onto a single spindle at 65-70 type 

A shore hardness through the use of a wiper guide and 

traverse guide to form the multi-pick yarn package 100. 

FIG. 3 is a multi-pick yam package view 350 showing the 

parallel configuration of the adjacent texturized yarns and 

their crossing wind angle within the multi-pick yam package, 

imposed by the wiper guide and traverse guide of FIG. 1, 

respectively, according to one or more embodiments. Particularly, FIG. 3 further illustrates a crossing wind angle 300 

(denoted 0), and a bobbin 302. 

In the embodiment of FIG. 3, the multi-pick yam package 

100 is shown wound with the adjacent parallel yams 101 

comprising two of the texturized yarns 122. The adjacent 

parallel yarns 101 may be wound onabobbin302. Thebobbin 

may also he a strait or a tapered bobbin. The crossing wind 

angle 300 may be the acute angle formed at the intersection 

between the adjacent parallel yarns 101 deposited in a first 

pass of the traverse guide 126 and the adjacent parallel yams 

101 in a subsequent pass of the traverse guide 126, as shown 

in FIG. 3. 

FIG. 4 is a binary simultaneous weft insertion view 450 of 

an exemplarily use of the multi-pick yarn package of FIG. 3 in 

which two adjacent parallel yarns forming a binary pick yarn 

package are fed into an air jet loom apparatus such that a 

primary nozzle simultaneously propels two picks across a 

warp shed of the loom apparatus in a single pick insertion 

event, according to one or more embodiments. Particularly, 

FIG. 4 further illustrates a binary pick yarn package 400 (e.g., 

the multi-pick yam package 100 wound with two of the 

texturized yams 122), a parallel binary yams 401, an accumulator 402, a weft source 403 a cross section of a pick 

insertion apparatus 404 (e.g., an airjet pick insertion apparatus), a primary nozzle 406 comprised of a fixed main nozzle 

407 and a moveable main nozzle 409, a nozzle injector 408, a 

yarn guide 410, a warp shed 412, a reed apparatus 414 (e.g., 

a profiled reed ofthe airjet loom), a single pick insertion event 

416, a relay nozzle 418, a textile 420, a fabric fell 422, and a 

warp/weft interlacing 424. 

The loom apparatus 405 (e.g., a rapier loom, a bullet loom, 

an air jet loom) may accept a weft source 403 supplying the 

adjacent parallel yams 101. In the embodiment of FIG. 4, the 

loom apparatus 405 may be an airjet loom apparatus (e.g., a 

Picanol Omni Plus®, a Picanol Omni Plus® 800) and the weft 

source 403 may be the binary pick yam package 400, which 

is the multi-pick yam package 100 wound with two of the 

adjacent parallel yarns 101 in accordance with the process of 

FIG. 1 and FIG. 2. The two of the adjacent parallel yams 101 

drawn from the binary pick yarn package 400 and fed into the 

loom apparatus 405 may be referred to as the parallel binary 

yarns 401. 

8 

The parallel binary yams 401 may be fed into the air jet 

loom apparatus and the elements thereof in accordance with 

ordinary practice to one skilled in the art. FIG. 4 illustrates 

some of the elements of an air jet loom apparatus that may 

5 interact with the parallel binary yams 401 such as the accumulator 402, the primary nozzle 406, the fixed main nozzle 

407, the moveable main nozzle 409, the profiled reed (e.g., the 

reed apparatus 414 of the airjet loom) and the relay nozzles 

418. 

10 For example, the parallel binary yams 401 from the binary 

pick yam package 400 may be fed into an accumulator 402 of 

the airjet pick insertion apparatus. The accumulator 402 may 

be designed to collect and hold in reserve between each of the 

15 single pick insertion events 416 a length of the parallel binary 

yarns 401 needed to cross the warp shed 412 with a minimal 

unwinding resistance. Next, the parallel binary yams 401 

may pass into the pick insertion apparatus 404 (in the embodiment of FIG. 4, a cross section of an air jet pick insertion 

20 apparatus is shown). The primary nozzle 406 may be comprised of one or more individual nozzles. In the embodiment 

of FIG. 4, the primary nozzle 406 is comprised of the fixed 

main nozzle 407 and the moveable main nozzle 409. The 

primary nozzle 406 may accept the adjacent parallel yarns 

25 101 through a yarn guide 410 of a nozzle injector 408 that 

may be present in both the fixed main nozzle 407 and the 

moveable main nozzle 409. In an alternate embodiment, the 

primary nozzle 406 may be comprised of a single nozzle. 

Air entering the fixed main nozzle 407 and/or the moveable 

30 main nozzle 409 may drive back the nozzle injector 408 and 

propel the parallel binary yams 401 across the warp shed 412 

of the loom apparatus 405. The airflow of the primary nozzle 

may be adjusted to between 12 Nm /hour to 14 Nm ihour. 

The airflow of the fixed main nozzle 407 may be adjusted to 

35 between 12 Nm /hour to 14 Nm thour and a drive time of the 

relay valves (not shown in the embodiment of FIG. 4) may be 

adjusted to between 90° and 135°. 

The parallel binary yams 401 may enter the warp shed 412 

of the loom apparatus 405. With the air jet pick insertion 

40 apparatus of FIG. 4, the parallel binary yams 401 may be 

aided in crossing the warp shed 412 by a plurality of relay 

nozzles 418 associated with a reed apparatus 414 that, to aid 

in gaseous conveyance of the picks, may be a profiled reed. 

Each of the relay nozzles 418 maybe adjusted to between 100 

45 mbar to 14 mbar. 

The parallel binary yams 401 drawn from the multi-pick 

yarn package may cross the warp shed 412 in the single pick 

insertion event 416. The single pick insertion event 416 is the 

operation and/or process of the pick insertion apparatus 404 

50 that is known in the art to be ordinarily associated with the 

projection of yarns (or yarns comprised of multiple yarns 

twisted together) across the warp shed 412. For example, the 

yarn threaded through the yam guide 410 of the primary 

nozzle 406 may be a single yarn that yam may be projected 

55 across the warp shed 412 of the loom apparatus 405 in a single 

burst (or rapid timed succession of bursts) of pressurized air 

from a single of the primary nozzles 406. In another example, 

the single pick insertion event 416 may be one cycle of a 

rapier arm (e.g., a rapier pick insertion apparatus) through the 

60 warp shed 412. 

Upon crossing the warp shed 412 of the loom apparatus 

405, the reed apparatus 414 may "beat up" (e.g., perform a 

beat up motion) the parallel binary yams 401, forcing them 

into the fabric fell 422 (also known as "the fell of the cloth") 

65 of the textile 420 that the loom apparatus 405 may be producing. The beat up motion of the reed apparatus 414 may form 

the warp/weft interlacing 424 of the warp yams 426 and the 

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9 

parallel binary yams 401 (e.g., the weft yams), producing an 

incremental length of the textile 420. 

FIG. 5 is a quaternary simultaneous weft insertion view 

550 of an exemplarily use of more than one of the multi-pick 

yarn package of FIG. 3 in which two of the binary pick yarn 

packages of FIG. 4 are fed into an air jet loom apparatus such 

that a primary nozzle simultaneously propels four picks 

across a warp shed of the loom apparatus in a single pick 

insertion event, according to one or more embodiments. Particularly, FIG. 5 further illustrates the use of a parallel quaternary yams 501. 

In FIG. 5, the weft source 403 may be two of the binary pick 

yarn packages 400 of FIG. 4, each supplying two of the 

parallel binary yarns 401 (e.g., four of the texturized yams 

122), that may be fed into the pick insertion apparatus 404 of 

the loom apparatus 405 (in the embodiment of FIG. 5, the air 

jet loom) such that the two parallel binary yams 401 may 

become the parallel quaternary yam 501. Therefore, four of 

the texturized yarns 122 may be threaded through the yarn 

guide 410 of the primary nozzle 406, and all four of the 

texturized yams 122 may be projected across the warp shed 

412 in a single burst of pressurized air from the primary 

nozzle 406. To further illustrate, the four of the texturized 

yarns 122 (e.g., the parallel quaternary yams 501) shown in 

FIG. 5 may be substantially adjacent and parallel as opposed 

to twisted around one another. 

In an alternate embodiment not shown in FIG. 4 or FIG. 5, 

the weft source 403 of the loom apparatus 405 may be three or 

more of the multi-pick yam packages 100. For example, the 

well source 403 may be four binary pick yarn packages 400. 

In such a case, eight of the texturized yarns 122 may be 

projected across the warp shed 412 during the single pick 

insertion event 416. In one embodiment, the highest thread 

counts (e.g., 800, 1000) may he yielded by using four of the 

binary pick yarn packages 400 as the weft source 403. 

In yet another embodiment not shown in FIG. 4 or FIG. 5, 

there may also be an odd number of the texturized yams 122 

(e.g., a tertiary parallel yarns) propelled across the warp shed 

412 in the single pick insertion event 416, for example of the 

well source 403 was composed of a the single-pick yarn 

package along with one of the binary pick yam packages 400 

of FIG. 4. The tertiary parallel yams may also result where the 

multi pick yam package 100 is wound with three of the 

texturized yarns 122 by the process of FIG. 1 and FIG. 2. In 

addition, the deniers of the texturized yams 122 wound on the 

multi-pick yam package 100 may be heterogeneous. 

It will be recognized to one skilled in the art that the loom 

apparatus 405 may have tandem, multiple, or redundancies of 

the pick insertion apparatuses 404 which may insert yams in 

an equal number of the single pick insertion events 416. For 

example, an air jet loom apparatus may have multiple of the 

primary nozzles 406 (e.g., four, eight). A number of the primary nozzles 406 may each insert the adjacent parallel yams 

101 in a corresponding number of the single pick insertion 

events 416 before the reed apparatus 414 beats the adjacent 

parallel yams 101 into the fabric fell 422. For example, an air 

jet loom utilizing six of the primary nozzles 406, with each of 

the primary nozzles 406 supplied by one of the binary pick 

yarn packages 400, may project six the parallel binary yams 

401 across the warp shed 412 in six of the single pick insertion 

events 416 that are distinct. In such an example, twelve of the 

texturized yams 122 would be beat into the fabric fell 422 

during the beat up motion of the reed apparatus 414. In one 

embodiment, the highest thread counts (e.g., 800, 1000) may 

be yielded by using multiple of the pick insertion apparatuses 

404 (e.g., four, each projecting two of the adjacent parallel 

10 

yarns 101 across the warp shed 412 before the reed apparatus 

414 carries out the beat-up motion). 

FIG. 6 is a pseudo-plain weave diagram view 650 and 

textile edge view 651 that demonstrates the resulting 1x2 

5 weave when the adjacent parallel yam pair from the binary 

pick yam package of FIG. 4 is conveyed across the warp shed 

of a loom apparatus configured to interlace warp and weft 

yarns after a single pick insertion event, according to one or 

more embodiments. Particularly, FIG. 6 further illustrates a 

10 woven fabric interlacing diagram 600 having sections with a 

weft under warp 602, a weft over warp 604, a weft direction 

606, and a warp direction 608. 

FIG. 6 shows the woven fabric interlacing diagram 600 that 

Is may result when a loom apparatus (e.g., the loom apparatus 

405) is configured to interlace the warp yams 426 and the 

adjacent parallel yarns 101 drawn from the binary pick yam 

package 400 of FIG. 4 after a single pick insertion event 416. 

Because two of the texturized yams 122 may be wound on the 

20 binary pick yam package 400, the resulting woven fabric 

interlacing may be a "1 by 2" weave with the weft under warp 

602 and weft over warp 604 alternating after each of the warp 

yarns 426 in the weft direction 606 and alternating after each 

two of the texturized yarns 122 in the warp direction 608. For 

25 example, while the loom apparatus may be traditionally configured to produce a textile with a plain wave (e.g., having a 

woven fabric interlacing diagram 600 of alternating weft 

under warp 602 and weft over warp 604 in both the weft 

direction 606 and the warp direction 608, similar to chess 

30 board), the result will be a the I by 2 "pseudo-plain weave" 

woven fabric interlacing diagram 600 of FIG. 6. 

The warp yams 426 of a textile produced using the multipick yam package 100 (e.g., the textile 420) may be comprised of natural or synthetic fibers, and the weft yarns may be 

35 polyester weft yarns (e.g., the adjacent parallel yarns 101 

comprised of multiple of the texturized yams 122). In one 

preferred embodiment, the warp yarns may he made of cotton. 

The textile produced from the multi-pick yam package 100 

40 may have between 90 and 235 warp yarn ends per inch, 

between 100 and 765 picks per inch, and may have a warpto-fill ratio between 1:2 and 1:4 (in other words, 1 warp yam 

per every 4 weft yams). The textile produced using the multipick yarn package 100 may have a thread count of between 

45 200 to 1000, a minimum tensile strength of 17.0 kg to 65.0 kg 

(about 37.5 lbs to 143.5 lbs) in the warp direction 608, and a 

minimum tensile strength of 11.5 kg to 100.0 kg (about 25.4 

lbs to 220.7 lbs) in the weft direction 606. In one or more 

embodiments the textile manufactured using the multi-pick 

50 yarn package 100 may have a composition of 45-49% texturized polyester yam (e.g., the texturized yam 122) and 5165

cotton yarn. 

The partially oriented polyester yam 103 (that becomes the 

texturized yam 122 after undergoing operations 200 through 

55 216 of FIG. 2) may have multiple filaments and may have a 

denier of between 15 and 50. In one preferred embodiment, 

the partially oriented polyester yarn 103 may have about a 

denier of about 20 and have about 14 filaments. 

The resulting fabric produced may be of exceptionally high 

60 quality compared to prior-art cotton-synthetic hybrid weaves 

due to its high thread count. To further increase quality and 

comfort of the textile, the fabric may be finished by brushing 

the surface to increase softness (a process known as "peaching" or "peach finishing"). In addition, various other finishing 

65 methods maybe used in association with the textile produced 

from the multi-pick yarn package 100 to increase the resulting textile's quality. 

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In one embodiment, a woven textile fabric includes from 

90 to 235 ends per inch warp yams and from 100 to 765 picks 

per inch multi-filament polyester weft yams. The warp yams 

maybe made of a cotton material, and may have a total thread 

count is from 300 to 1000. The woven textile fabric may be 

made of multi-filament polyester yams having a denier of 20 

to 65. The woven textile fabric may have multi-filament polyester yams having a denier of 15 to 35. The woven textile 

fabric may also have multi-filament polyester yams have a 

denier of 20 to 25. 

Additionally, the multi-filament polyester yarns may contain 10 to 30 filaments each. The woven textile fabric may 

have a minimum tensile strength in a warp direction of 17 

kilograms to 65 kilograms and a minimum tensile strength in 

a weft direction of 11.5 kilograms to 100 kilograms. The 

woven textile fabric may have a warp-to-fill ratio that is 

between 1:2 to 1:4. 

In another aspect, a method of weaving a fabric includes 

drawing multiple polyester weft yarns from a weft source to 

a pick insertion apparatus of a loom apparatus. The method 

also includes conveying by the pick insertion apparatus the 

multiple polyester weft yarns across a warp shed of the loom 

apparatus through a set of warp yarns in a single pick insertion 

event of the pick insertion apparatus of the loom apparatus 

and beating the multiple polyester weft yams into a fell of the 

fabric with a reed apparatus of the loom apparatus such that 

the set of warp yams and/or the multiple polyester well yams 

become interlaced into a woven textile fabric. The method 

forms the woven textile having from 90 to 235 ends per inch 

warp yams and from 100 to 765 picks per inch multi-filament 

polyester well yams. 

The denier of the polyester weft yarns may be between 15 

and 50. The well source may be a well yarn package in which 

the multiple polyester well yams are wound substantially 

parallel to one another and substantially adjacent to one 

another to enable the simultaneous inserting of the multiple 

polyester weft yams during the single pick insertion event of 

the pick insertion apparatus of the loom apparatus. Further, 

the number of the multiple polyester well yams wound substantially parallel to one another and substantially adjacent to 

one another on the well yarn package may be two. The number of the multiple polyester weft yarns conveyed by the pick 

insertion apparatus across the warp shed of the loom apparatus through the set of warp yarns in the single pick insertion 

event of the pick insertion apparatus of the loom apparatus 

may be between two and eight. 

Additionally, the pick insertion apparatus of the loom 

apparatus may be an air jet pick insertion apparatus. The 

multiple polyester weft yams may be wound on the yarn 

package at an angle of between 15 and/or 20 degrees to enable 

the simultaneous inserting of the multiple polyester well 

yarns during the single pick insertion event of the pick insertion apparatus of the loom apparatus. Additionally, the multiple polyester weft yams may be wound on the yarn package 

at a type A shore hardness of between 65 to 70 to enable the 

simultaneous inserting of the multiple polyester weft yams 

during the single pick insertion event of the pick insertion 

apparatus of the loom apparatus. Further, the multiple polyester well yams may be treated with a conning oil comprising 

a petroleum hydrocarbon, an emulsifier and/or a surfactant to 

enable the simultaneous inserting of the multiple polyester 

well yarns during the single pick insertion event of the pick 

insertion apparatus of the loom apparatus. The pick insertion 

apparatus of the loom apparatus may be a rapier insertion 

apparatus and/or a bullet insertion apparatus. 

An airflow of a primary nozzle and/or a fixed nozzle of the 

air jet pick insertion apparatus pick insertion apparatus may 

12 

be adjusted to between 12 Nm /hr to 14 Nm /hr to enable the 

simultaneous inserting of the multiple polyester weft yarns 

during the single pick insertion event of the pick insertion 

apparatus of the loom apparatus. The airflow of each relay 

S nozzle in the air jet pick insertion apparatus pick insertion 

apparatus may be adjusted to between 100 and/or 140 millibars to enable the simultaneous inserting of the multiple 

polyester well yams during the single pick insertion event of 

the pick insertion apparatus of the loom apparatus. A drive 

10 time of a drive time of a relay valve of the airjet pick insertion 

apparatus pick insertion apparatus may be adjusted to 

between 90 degrees and/or 135 degrees to enable the simultaneous inserting of the multiple polyester weft yarns during 

the single pick insertion event of the pick insertion apparatus 

is of the loom apparatus, and the multiple polyester weft yarns 

may have a denier of 22.5 with 14 filaments. 

The multiple polyester weft yarns may be treated with a 

primary heater heated to approximately 180 degrees Celsius 

to enable the simultaneous inserting of the multiple polyester 

20 well yams during the single pick insertion event of the pick 

insertion apparatus of the loom apparatus, and the multiple 

polyester well yam may be treated with a cooling plate at a 

temperature of between 0 and 25 degrees Celsius subsequent 

to the treating with the primary heater. 

25 In yet another aspect, a bedding material having the combination of the "feel" and absorption characteristics of cotton 

and the durability characteristics of polyester with multifilament polyester well yarns having a denier of between 15 

and 50 and cotton warp yams woven in a loom apparatus that 

30 simultaneously inserts multiple of the multi-filament polyester well yams during a single pick insertion event of the loom 

apparatus in a parallel fashion such that each of the multiple 

polyester well yarns maintain a physical adjacency between 

each other during the single pick insertion event, increasing 

35 the thread count of a woven fabric of the bedding material 

based on the usage of multi-filament polyester well yarns 

with a denier between 15 and 50. The bedding is a woven 

textile fabric that includes from 90 to 235 ends per inch warp 

yarns and from 100 to 765 picks per inch multi-filament 

40 polyester weft yams. 

The total thread count of the bedding material may be from 

300 to 1000 and each multi-filament polyester yarn count of 

the bedding material may have from 10 to 30 filaments each. 

Although the present embodiments have been described 

45 with reference to specific example embodiments, it will be 

evident that various modifications and changes may be made 

to these embodiments without departing from the broader 

spirit and scope of the various embodiments. In addition, the 

process flows depicted in the figures do not require the par50 ticular order shown, or sequential order, to achieve desirable 

results. In addition, other operations may be provided, or 

operations may be eliminated, from the described flows, and 

other components may be added to, or removed from, the 

described systems. Accordingly, other embodiments are 

55 within the scope of the following claims. 

What is claimed is: 

1. A woven textile fabric comprising: 

from 90 to 235 ends per inch warp yarns; and 

from 100 to 765 picks per inch multi-filament polyester 

60 weft yams; 

wherein the picks are woven into the textile fabric in groups 

of at least two multi-filament polyester weft yarns running parallel to each other, 

wherein the multi-filament polyester well yarns are wound 

65 substantially parallel to one another and substantially 

adjacent to one another on a multi-pick yam package to 

enable the simultaneous inserting of the multi-filament 

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US 9,131,790 B2 

13 

polyester weft yams during a single pick insertion event 

of a pick insertion apparatus of a loom apparatus, 

wherein the number of the multi-filament polyester weft 

yarns wound substantially parallel to one another and 

substantially adjacent to one another on the well yarn 

package is two, 

wherein the number of the multi-filament polyester weft 

yarns conveyed by the pick insertion apparatus across a 

warp shed of the loom apparatus through a set of warp 

yarns in the single pick insertion event of the pick insertion apparatus of the loom apparatus is between two and 

eight, 

wherein the pick insertion apparatus of the loom apparatus 

is an air jet pick insertion apparatus, 

wherein the multi-filament polyester weft yams are wound 

on the multi-pick yam package at an angle ofbetween 15 

and 20 degrees to enable the simultaneous inserting of 

the multi-filament polyester weft yarns during the single 

pick insertion event of the pick insertion apparatus of the 

loom apparatus, and 

wherein the multi-filament polyester weft yams are wound 

on the multi-pick yarn package at a type a shore hardness 

of between 65 to 70 to enable the simultaneous inserting 

of the multi-filament polyester weft yarns during the 

single pick insertion event of the pick insertion apparatus of the loom apparatus. 

2. The woven textile fabric of claim 1: 

wherein the warp yams are made of a cotton material. 

3. The woven textile fabric of claim 2: 

wherein a total thread count is from 300 to 1000. 

4. The woven textile fabric of claim 1: 

wherein the multi-filament polyester yarns have a denier of 

20 to 65. 

5. The woven textile fabric of claim 1: 

wherein the multi-filament polyester yarns have a denier of 

15 to 35. 

6. The woven textile fabric of claim 2: 

wherein the multi-filament polyester yarns have a denier of 

20 to 25. 

7. The woven textile fabric of claim 6: 

wherein the multi-filament polyester yarns contain 10 to 30 

filaments each. 

8. The woven textile fabric of claim 7: 

wherein the fabric has a minimum tensile strength in a warp 

direction of 17 kilograms to 65 kilograms, 

wherein the fabric has a minimum tensile strength in a weft 

direction of 11.5 kilograms to 100 kilograms, and 

wherein the fabric has a warp-to-fill ratio is between 1:2 to 

1:4. 

9. The woven textile fabric of claim 1: 

wherein weft yams within each group run parallel to each 

other in a plane which substantially includes the warp 

yarns. 

10. The woven textile fabric of claim 1: 

wherein each of the groups is made up of four multifilament polyester weft yams. 

11. A woven textile fabric comprising: 

from 90 to 235 ends per inch warp yarns; and 

from 100 to 765 picks per inch multi-filament polyester 

weft yarns; 

14 

wherein the picks are woven into the textile fabric in groups 

of two multi-filament polyester weft yams running parallel to each other, 

wherein the multi-filament polyester weft yarns are wound 

5 substantially parallel to one another and substantially 

adjacent to one another on a multi-pick yam package to 

enable the simultaneous inserting of the multi-filament 

polyester well yarns during a single pick insertion event 

of a pick insertion apparatus of a loom apparatus, 

10 wherein the number of the multi-filament polyester weft 

yarns wound substantially parallel to one another and 

substantially adjacent to one another on the weft yarn 

package is two, 

15 wherein the number of the multi-filament polyester weft 

yarns conveyed by the pick insertion apparatus across a 

warp shed of the loom apparatus through a set of warp 

yarns in the single pick insertion event of the pick insertion apparatus of the loom apparatus is two, 

20 wherein the multi-filament polyester weft yarns are wound 

on the multi-pick yam package at an angle ofbetween 15 

and 20 degrees to enable the simultaneous inserting of 

the multi-filament polyester weft yams during the single 

pick insertion event of the pick insertion apparatus ofthe 

25 loom apparatus, and 

wherein the multi-filament polyester well yarns are wound 

on the multi-pick yam package at a type a shore hardness 

of between 65 to 70 to enable the simultaneous inserting 

of the multi-filament polyester well yarns during the 

30 single pick insertion event of the pick insertion apparatus of the loom apparatus. 

12. The woven textile fabric of claim 11: 

wherein the warp yarns are made of a cotton material. 

35 13. The woven textile fabric of claim 12: 

wherein a total thread count is from 300 to 1000. 

14. The woven textile fabric of claim 11: 

wherein the multi-filament polyester yams have a denier of 

20 to 65. 

40 15. The woven textile fabric of claim 11: 

wherein the multi-filament polyester yams have a denier of 

15 to 35. 

16. The woven textile fabric of claim 12: 

wherein the multi-filament polyester yams have a denier of 

45 20 to 25. 

17. The woven textile fabric of claim 16: 

wherein the multi-filament polyester yarns contain 10 to 30 

filaments each. 

18. The woven textile fabric of claim 17: 

50 wherein the fabric has a minimum tensile strength in a warp 

direction of 17 kilograms to 65 kilograms, 

wherein the fabric has a minimum tensile strength in a weft 

direction of 11.5 kilograms to 100 kilograms, and 

wherein the fabric has a warp-to-fill ratio is between 1:2 to 

55 1:4. 

19. The woven textile fabric of claim 11: 

wherein well yams within each group nm parallel to each 

other in a plane which substantially includes the warp 

yarns. 

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