Patent Grant
9181652
Sheets, pillowcases, and other bedding products used in the hospitality industry are changed and washed on a frequent basis due to the high volume of guests staying for short term intervals. To meet stringent hospitality standards for cleanliness, such hospitality linens are often subjected to a laundering process that is much more strenuous than the washing process used in an ordinary residential home setting. Hospitality laundering often entails much higher temperatures than residential washing and commonly employs commercial grade surfactants that are much more severe than their residential counterparts. Due to the extreme strain upon products during hospitality laundering, there is a high likelihood that the color of any colored portion of these products will fade and/or bleed onto, crock, or otherwise stain other portions of the pillowcase, sheet, or other item during use, washing, and/or drying. Accordingly, any hospitality product that includes any color must exhibit substantial color-fastness.
The term “colorfastness” is used in the textiles industry to denote the degree to which a dyed article will retain or maintain its original finished hue and resist fading or running of color over time due to washing, drying, exposure to sun or other bright light, and/or other types of wear during the useful life of the article. Factors known in the industry to affect colorfastness primarily include the types of fibers, dyes, and treatments used for initially producing an article and setting its color. However, although these factors can be identified on a general level, the details and exact modifications necessary to achieve improvements in colorfastness are infrequently so easy to articulate. As such, even though extensive testing and significant effort has been dedicated to advancing the art of colorfastness, articles with multiple colors are not known to be used in the hospitality industry at present.
The following presents a simplified summary of some embodiments of the invention in order to provide a basic understanding of the invention. This summary is not an extensive overview of the invention. It is not intended to identify key/critical elements of the invention or to delineate the scope of the invention. Its sole purpose is to present some embodiments of the invention in a simplified form as a prelude to the more detailed description that is presented later.
Disclosed is a method of producing a bedding product including a bedding product body and a colored hem. The method can include selecting a hem fabric at least in part based upon composition of the fabric. The composition of the fabric can be selected from the group consisting of cotton-only, blends of cotton and polyester, and blends of cotton and non-cotton material. The method can also include selecting a combination of dyes at least in part based upon the composition of the fabric; if the composition contains cotton, the combination of dyes includes a first subcombination of dyes, and if the composition contains polyester, the combination of dyes includes a second subcombination of dyes. The method can also include preparing the hem fabric by mercerization if the selected fabric contains cotton. The method can also include applying the combination of dyes to the selected fabric. The method can also include passing the fabric through a multiple stage wash to substantially remove unfixed dyes from the hem fabric. The method can also include attaching a hem comprising hem fabric to the bedding product body.
Also disclosed is a bedding product having a colored hem attached to a body. The colored hem can include fabric produced according to a method. The method can include mercerizing the fabric, applying dyes to the fabric, and purging the fabric such that substantially all wash liquor is removed from the fabric.
For a fuller understanding of the nature and advantages of the present invention, reference should be made to the ensuing detailed description and accompanying drawings.
In the following description, various embodiments of the present invention will be described. For purposes of explanation, specific configurations and details are set forth in order to provide a thorough understanding of the embodiments. However, it will also be apparent to one skilled in the art that the present invention may be practiced without the specific details. Furthermore, well-known features may be omitted or simplified in order not to obscure the embodiment being described.
Disclosure herein is directed to a bedding product having a colored hem and methods of making the same. For such a bedding product to be viable for use in the hospitality industry, the product needs to exhibit substantial colorfastness over a significant number of industrial washes. While the exact number of washes may vary between hospitality providers, it is not uncommon for the target life span of a bedding product to exceed 50 industrial washes. Industrial washing includes laundry procedures established in a commercial setting established to wash products such as towels, table linens, and sheets used by providers in the hospitality industry such as nursing homes, rentals, and hospitals. Depending on the size of the facility, an industrial wash setup can involve washing several hundred pounds per shift or tens of thousands of pounds per shift. Additionally, while two different hospitality properties will likely use two slightly different settings for their industrial washes, industrial washes across the hospitality industry share a common set of parameters. For instance, industrial washing frequently involves extreme wash temperatures ranging from 40 to 160° F. (e.g., many nursing homes are known to use temperatures of 160° F. for increased sanitization of their products, while many hotels tend to wash in a more moderate temperature of around 130° F.). Additionally, industrial washing can involve surfactants as harsh as Sodium Hypochlorite with up to 0.027% available free chlorine (e.g., nursing homes frequently use significant amounts of bleach and may reach such concentrations, while hotels vary whether or not they utilize bleach during their laundering). Furthermore, industrial washing can involve a variety of PH levels, ranging from as low 5.5 as to as high as to 12.5. For example, PH commonly varies depending on the type of detergent used. Because many detergents require a PH in the 10 to 11 range, the washing process on many occasions also involves neutralizing by subsequently introducing an acid (PH of 5 to 6) to bring the PH back down to 7. As such, a product designed to withstand industrial washes (which can vary significantly between hospitality providers) is designed to withstand washes that include just one, multiple, or all of these parameters. Regardless, bedding products in accordance with embodiments as described further herein exhibit colorfastness when subjected even to 50 industrial washes.
Referring now to the drawings, in which like reference numerals represent like parts throughout the several views,
As will be appreciated by one skilled in the art, a number of factors must be taken into consideration when fabricating textiles. Variations in the fabric—including, but not limited to, composition, weight, or size—may necessitate requisite adjustments in various variables—including, but not limited to, times, temperatures, or concentrations—in order to achieve comparable results. To accommodate such variations and adjustments, mainly general terms are used in initial descriptions herein, and a number of exemplary results are subsequently described in more detail in an “Examples” section.
Selecting the fabric 202 can involve selecting a fabric based at least in part upon the fabric's composition. Cotton is a popular material for bedding products in the hospitality industry, and in embodiments, the selected fabric comprises cotton. Furthermore, polyester is a material commonly combined with cotton to modify the final qualities (e.g., strength) of fabrics used in the hospitality industry, and in various embodiments the fabric selected is a blend of cotton and polyester (also referred to as a cotton-poly blend). However, compositions are not limited to cotton and cotton-poly blends, and it is contemplated that the fabric could also be selected from a blend of cotton and non-cotton material.
Selecting dyes 204 during the color fasting method 200 can involve a dye selection method 300.
The terms “vat dyes” and “disperse dyes” are well known in the art of dyeing textiles. As used herein, the term “select vat dyes” refers to the group of vat dyes consisting essentially of violanthrones, anthraquinone, anthraquinone carbazoles, and indanthrones. Furthermore, in many embodiments, dyes used when polyester is present in the fabric include high-energy disperse thermofixation dyes.
Preparing the fabric 206 during the color fasting method 200 can involve a fabric preparation method 400.
In embodiments, pre-treatment 402 can be utilized to counteract effects resulting from the initial production of the fabric. In embodiments, pre-treatment can include one or both of singeing and desizing.
Singeing can involve exposing the fabric to at least one flame. Often hairy or extruding fibers result from a fabric production process, such as where fibers are spun together to make threads. In the process, many fibers end up not fully aligned in the thread direction, and the parts of these misaligned fibers that stick out from the thread give the thread a hairy appearance. During singeing, the face and/or the back of the fabric can be singed so as to burn these extruding fibers extending from the fabric and so reduce the number of them. Accordingly, singeing can remove extraneous fibers to improve the texture and characteristics of the fabric in various embodiments.
Desizing can involve removing a sizing agent used during the fabric production process. In many fabric production processes, fibers, yarns, or threads are coated with a sizing agent (such as starch or PVA—Polyvinyl alcohol) to improve the strength of the components while being combined into fabric. However, this coating can interfere with penetration of dyes into the fibers when applying dyes. Accordingly, in embodiments, desizing involves passing the fabric through a quench bath comprising a desizing agent to remove a residual amount of a sizing agent remaining on the fabric from production of the fabric. The desizing agent generally depends upon the sizing agent. For example, to remove starch as a sizing agent, the fabric can be immersed into enzymes and allowed to sit for a sufficient amount of time (e.g., 12 hours) to allow the enzyme to break down the starch so that it can be removed with hot water. In contrast, PVA can be removed merely by the application of hot water. In some embodiments, pre-treatment 402 includes a singe portion immediately followed by a desizing quench bath which also acts to extinguish any smoldering fibers from the singe portion.
Bleaching 404 during the fabric preparation method 400 can involve a fabric bleaching method 500.
Mercerizing 406 can be utilized to alter the chemical structure of fibers (especially cotton) to improve their ability to absorb dye. Mercerizing 406 during the fabric preparation method 400 can involve a fabric mercerization method 600.
Applying the dyes 208 during the color fasting method 200 can involve a dye application method 700.
Thermofixating disperse dyes 708 during the dye application method 700 can involve a disperse dye thermofixation method 800.
Reacting select vat dyes 710 during the dye application method 700 can involve a select vat dye reaction method 900.
Treating the dyed fabric 210 during the color fasting method 200 can involve a dyed fabric treatment method 1000.
Dyed fabric treatment method 1000 can include stabilizing 1004. The stabilizing 1004 may be accomplished by applying a chain stenter to the dyed fabric. The stenter can pull the fabric in a width-wise direction to counteract any shrinking occurring during prior processing of the fabric. In various embodiments, the fabric is passed through a bath or pad with fabric softeners before entering the stenter. Use of such softeners can advantageously allow the stenter to stretch the fabric to a greater degree and accordingly counteract shrinking more effectively. The dyed fabric treatment method 1000 can also include drying 1006. In some embodiments, the stabilizing 1004 provides part of a time utilized for drying 1006. While part or all of the fabric drying 106 can occur while the fabric is passing through the stenter, in some embodiments, dryer cans are used as a supplement or substitution for drying 1006 the dyed fabric.
Drying cans can also or alternatively be used for optional drying at several different junctures during a color fasting method 200. For example, after washing 712 to complete the dye application method 700, the fabric may be dried before beginning a purging 1002 or a dyed fabric treatment method 1000. Drying can be a convenient expedient when subsequent pieces of machinery require additional preparation before use. However, on the other hand, relaying the fabric to subsequent pieces of machinery while the fabric is still wet can advantageously reduce energy costs associated with drying.
Referring to
Without further elaboration, it is believed that the skilled artisan can, using the description herein, make and use colorfast bedding products 100 in accordance with this disclosure. The following examples are included to provide additional guidance to those skilled in the art. These examples are provided as representative of the work and contribute to the teaching of the present disclosure. Accordingly, these examples are not intended to limit the scope of the present invention in any way.
Representative samples described herein were produced in accordance with the following exemplary embodiment of color fasting method 200. The representative samples were produced using a common combination of machinery, which will be described first with reference to methods and figures already described herein, followed by a presentation of test results demonstrating the properties of the representative samples. For the sake of brevity and meaningful comparison, discussion of the representative samples will be limited to 5 specific samples, each sample having a different color: Tan, Blue, Yellow, Orange, and Green.
In the exemplary execution of fabric selection 202, fabric having a composition of 60% cotton/40% polyester and a weight of approximately 3.75 oz. per square yard was selected. (Although embodiments need not be limited to this particular fabric, this fabric serves as an appropriate sample for bedding products since compositions having a cotton/polyester blend up to 40% polyester are common for bedding products and weights typically range from 3.0 to 4.5 oz. per square yard.) Based on this selected composition, exemplary execution of dye selection method 300 resulted in the conclusion 312 to use both disperse and select vat dyes in the final combination of dyes. Each of the five colors was composed from a combination of three disperse dyes and three select vat dyes. The combination of three select vat dyes used and the three select disperse dyes used in each colored sample is as follows:
In the exemplary execution of fabric preparation 206, the representative samples underwent pre-treatment 402 via a combined singeing and desizing machine fabricated under the trade name Osthoff. A flame in the machine singed the fabric of the representative samples on the face and back to remove hairy or extruding fibers, and the fabric immediately afterward passed through a quench bath to extinguish any smoldering fibers and to apply an enzyme to loosen and eat away starch remaining from manufacture of the fabric. The fabric was allowed to sit for 12 hours to allow the enzyme to break down the starch so that it could be removed with hot water.
Next, exemplary execution of bleaching 404 was achieved by an open-width bleach range fabricated under the trade name Benninger. The wash boxes in the first section of the open width bleach range provided hot water to wash off the starch broken down by enzymes in accordance with pre-wash 502. Subsequent portions of the open-width bleach range subjected the representative samples to additional steps in bleaching method 500, including saturating with caustic and steaming in an oxygen free environment for 30 to 45 minutes (504 and 506), washing to neutralize caustic from the fabric (508), saturating with peroxide and steaming in an oxygen free environment for 30 to 45 minutes (510 and 512), and washing to neutralize peroxide from the fabric (514).
Subsequently, exemplary execution of mercerizing 406 was performed according to mercerizing method 600 using a mercerizing line fabricated under the trade name Benniger-Dimensa. A Benniger-Dimensa roller impregnation section introduced hot caustic (sodium hydroxide in the 20-24% range, heated in the 140° F. range to allay thickness occurring at ambient temperatures) to the representative samples and provided adequate dwell time (602 and 604). A Benniger-Dimensa chain stenter was also used for stabilization (606) to stretch the sheeting to recover some of the width lost during impregnation and dwell time, followed by a Benniger-Dimensa washer/neutralizer to remove the caustic (608).
In the exemplary execution of dye application method 700, representative samples were then immersed (702) in a dye bath—containing disperse dyes and the select vat dyes listed above with respect to each color—using a Benniger-Kuster dye pad, which includes multi-rollers in the dye bath trough and S-roll technology upon exit of the dye bath trough. The representative samples were allowed to dwell (704) using a section of rollers outside of the dye bath and then dried (706) using infrared dryers to prevent migrations of both disperse and vat dyes. Thermofixation (708) of disperse dyes was accomplished by heating (802) the representative samples in a thermosol oven operated in the 390 to 420° F. range and allowing the representative samples to dwell (804) in said oven for a time—sufficient to allow complete penetration or sublimation of the disperse dyes into the polyester in the samples to prevent ring or surface dyeing—before cooling (806) to lock the disperse dye particles into the polyester yarns. Reacting the select vat dyes (900) for the representative samples was accomplished using a Benniger-Reacta Booster Pad with strong alkali solution (i.e., including sodium hydro sulphite in the 3.0 to 5.0 g/L range and sodium hydroxide in the 3.6 to 8.8 g/L range) to reduce (902) the select vat dyes to soluble state, followed with significant dwell time steaming (904) in an oxygen-free environment in a Benniger-Reacta Reactive Steamer, and oxidizing (906) the representative samples using peroxide in a line of seven Benniger-Extracta extractors to make the selected vat dyes insoluble again.
In the exemplary execution of treating the dyed fabric 201, the dyed fabric treatment method 1000 started with a purging 1002. In the exemplary execution of the purging 1002, the representative samples were passed through a wide-width, open, continuous line of seven Benniger-Extracta high-efficiency, high-temperature, high-flow, double-laced, counter-flowing, commercial, independent washer extractors with nip rolls. Each washer extractor was adjustable for water flow, surfactants, ph, and temperature, and a surfactant was used in the first of the seven washers. Each of the washer extractors was also capable of removing or exchanging 50-80% of the wash liquor carried by the representative samples upon entry into that particular washer extractor.
In the exemplary execution of stabilization 1004, the representative samples were introduced into an immersion pad containing fabric softeners and attached to a Benniger-Dimensa chain stenter to be stretched to counteract prior shrinkage occurring during prior processing of the samples. In the exemplary execution of drying 1006, dryer cans were also used to supplement drying occurring on the stenter.
In the exemplary execution of bedding product production method 1100, each of the representative samples was configured as a hem and attached to a separate plain body by single needle stitching comprising a minimum 30 count 2 ply 100% polyester disperse-dyed sewing thread. The completed bedding products having the representative samples were then tested to determine performance.
Testing and Results
Each of the bedding products having a representative sample was tested according to testing procedures standardized by the American Association of Textile Colorist and Chemist (AATCC) and the Association of Standard Test Method (ASTM). Specifically, each bedding product having a different colored hem was tested according to gray scale test AATCC 61, test number 5A “Colorfastness to commercial Laundering—Accelerated.” Shade change based on AATCC gray scale (i.e., a scale of 1-5, with 5 being no change) was recorded at different intervals corresponding to differing numbers of industrial launderings (IDL). The shade change results for the 5 different colors of the representative samples were:
Other variations are within the spirit of the present invention. Thus, while the invention is susceptible to various modifications and alternative constructions, certain illustrated embodiments thereof are shown in the drawings and have been described above in detail. It should be understood, however, that there is no intention to limit the invention to the specific form or forms disclosed, but on the contrary, the intention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention, as defined in the appended claims.
The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. The term “connected” is to be construed as partly or wholly contained within, attached to, or joined together, even if there is something intervening. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate embodiments of the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.
Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.
All references, including publications, patent applications, and patents, cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.
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