Comforter

Abstract

A comforter has a first fabric sheet and a second fabric sheet. Each of the fabric sheets include a knit cover layer formed from a base yarn, and knitted into this base layer is a fibrous fluffy yarn in such a manner that a looped pile results. The looped pile is then sheared to create a cut pile nap. The first and second fabric sheets are stitched together around a perimeter with perimeter stitching to contain a fill material between the first and second fabric sheets and within the perimeter stitching. The first and second fabric sheets are also stitched together via lateral stitching that extends laterally at least partially across the comforter at spaced longitudinal intervals, so that the first and second fabric sheets are connected via the longitudinal stitching and movement of the fill material is constrained.

Description

BACKGROUND OF THE INVENTION

Field of the Invention

This invention relates generally to comforters, and more particularly to a comforter that have a comfortable and unique feel that is superior to prior art comforters.

Description of Related Art

The prior art teaches various forms of comforters. However, the prior art does not teach a comforter that is constructed and knitted as described herein. The present invention fulfills these needs and provides further advantages as described in the following summary.

SUMMARY OF THE INVENTION

The present invention teaches certain benefits in construction and use which give rise to the objectives described below.

The present invention is a comforter comprising a first fabric sheet and a second fabric sheet, each comprising a knit cover layer formed from a base yarn, and knitted into this base layer is a fibrous fluffy yarn in such a manner that a looped pile results, and wherein the looped pile is then sheared to create a cut pile nap; wherein the first and second fabric sheets are stitched together around a perimeter with perimeter stitching, to contain a fill material between the first and second fabric sheets and within the perimeter stitching; and wherein the first and second fabric sheets are also stitched together via lateral stitching that extends laterally at least partially across the comforter at spaced longitudinal intervals, so that the first and second fabric sheets are connected via the longitudinal stitching and movement of the fill material is constrained.

In one embodiment, the comforter includes a polyester derived knit matrix, in one embodiment weighing a minimum of 180 grams per square meter, and preferably 280 grams per square meter. The weft of the knit matrix has been scratched and raised to produce a nap averaging 2 mm in height. The base yarn is preferably PBT and the fibrous yarn used in the pile is 100% polyester. The outer cover is sliver knit on a warp knitting machine to create a unique texture and feel. After knitting, the fibrous yarn is sheared to create a velvet-like pile.

A primary objective of the present invention is to provide a comforter having advantages not taught by the prior art.

Other features and advantages of the present invention will become apparent from the following more detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings illustrate the invention:

FIG. 1A shows a perspective view of a comforter according to one embodiment of the present invention;

FIG. 1B is a sectional view taken along lines 1B-1B in FIG. 1A;

FIG. 2 shows enlarged detail of the comforter according to one embodiment of the invention;

FIG. 3 shows a plan view of the bottom surface of one of a first or second fabric sheets;

FIG. 4 shows the different textures of the two polyester yarns used in the weaving process;

FIG. 5 shows the pile material prior to shearing; and

FIG. 6 shows a cross-sectional view of the warp knitting machine used to make the comforter of FIG. 1.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The above-described drawing figures illustrate the invention, a comforter that comprises a pair of fabric sheets stitched together and filled with fill material.

Referring now in detail to the drawings, FIG. 1A shows a perspective view of a comforter according to one embodiment of the present invention. FIG. 2A is a sectional view taken along line 1B-1B in FIG. 1A. As shown in FIGS. 1A-1B, the comforter 10 may be in the form of a first fabric sheet 16 and a second fabric sheet 17 stitched together in a generally rectangular shape; however, the comforter 10 may be in any shape and configuration (e.g., rounded, irregular, etc.). For the purposes of this application, the first and second fabric sheets 11a and 11b may be defined as two separate pieces of fabric (i.e., cut cloth) that are then stitched together, but the first and second fabric sheets 16 and 17 may also be construed to be one continuous piece of fabric that is delineated into “sheets” via folding and stitching, such that two “layers” are formed and stitched together out of a single sheet. Furthermore, a “patchwork” of more than two pieces of separated fabric may be stitched together to form first and second “sheets” for layering. Any of these options should be considered within the scope of the invention.

As shown in FIGS. 1A-2A, the first and second fabric sheets 16 and 17 each include a top surface 11a and a bottom surface 11b that extend to a perimeter 18, wherein each perimeter 18 is secured together via stitching 11c. Furthermore, the first and second fabric sheets 11a and 11b include lateral stitching 11d at intervals across the bodies of the first and second fabric sheets 16 and 17, within the perimeter.

The first and second fabric sheets 16 and 17 are also stitched together via lateral stitching 11d that extends laterally at least partially across the comforter 10 at spaced longitudinal intervals, so that the first and second fabric sheets 16 and 17 are connected via the longitudinal stitching 11d and movement of the fill material is constrained. The example of FIGS. 1A and 2A illustrates the stitching 11d as being formed in a single series of stitches connected to each other by connecting sections (which extend longitudinally), but other configurations may also be implemented. For example, the stitching 11d may be in the form of a plurality of lines which may be separate from and parallel to each other. The stitching 11d may alternatively be in the forms of geometric shapes (e.g., rectangles, circles, etc.), or it may be in the form of rows/columns along the body of each sheet, or any other suitable configuration devised by one skilled in the art.

As shown in FIG. 1B, the comforter 10 further comprises a fill material 11e between the first and second fabric sheets 16 and 17 and within the perimeter stitching 11c. In some embodiments, the fill material 11e is in the form of hollow siliconized polyester fibers, but any suitable material may be used, including natural and/or synthetic alternatives.

FIG. 2 shows enlarged detail of the comforter 10 according to one embodiment of the invention, and FIG. 3 shows a plan view of the bottom surface of the first or second fabric sheets 16 and 17. FIGS. 2 and 3 illustrate a knit cover layer 11 of the first and second fabric sheets. The cover layer 11 is formed from a base yarn 12 with a stretch, such as PBT (polybutylene tetraphthalate). In this embodiment, knitted into this base layer 12 in a sliver knitting process is a fibrous fluffy polyester yarn 13 in such a manner that a looped pile 9 results after combing or scratching the knit. This looped pile 9 is then sheared as shown in FIG. 6 to create a cut pile nap.

FIG. 4 shows the different textures of the two polyester yarns 12 and 13 used in the weaving process. FIG. 4 shows an enlarged view showing the different textures of the yarns 12 and 13 used to create the cover layer 11. The dark strand represents the PBT base yarn 12, and the lighter strands represent the fibrous polyester yarn 13 that is used to create the pile. The structure of the knitted fabric 11 is shown in FIG. 3, prior to shearing the loops 9 to create the cut pile texture.

FIG. 5 shows the pile material 14 prior to shearing, and FIG. 6 shows a cross-sectional view of a warp knitting machine 20 used to create the cover layer 11 (shown in FIG. 1). This is a standard warp knitting machine such as the Karl Mayer HKS 3-S, E28. The machine 20 knits the yarns 12 and 13 described above into a fabric 11 that has a unique texture, using a knitting speed of 2000 revolutions per minute. The machine 20 consists of a compound needle bar 1, a closing wire bar 2, a knockover sinker bar 3, a supporting bar 4, an oscillating brush bar 5 and a pile sinker bar 6. The machine 20 knits base yarn 12 and fibrous polyester yarn 13 into a looped pile knit 9.

In one embodiment, the comforter 10 includes a polyester derived knit matrix, in one embodiment weighing a minimum of 180 grams per square meter, and preferably 280 grams per square meter. The weft of the knit matrix has been scratched and raised to produce a nap averaging 2 mm in height. The base yarn 12 is preferably PBT and the fibrous yarn 13 used in the pile in this embodiment is 100% polyester. The outer cover is sliver knit on a warp knitting machine 20 to create a unique texture and feel. After knitting, the fibrous yarn 13 is sheared to create a velvet-like pile.

The title of the present application, and the claims presented, do not limit what may be claimed in the future, based upon and supported by the present application. Furthermore, any features shown in any of the drawings may be combined with any features from any other drawings to form an invention which may be claimed.

As used in this application, the words “a,” “an,” and “one” are defined to include one or more of the referenced item unless specifically stated otherwise. The terms “approximately” and “about” are defined to mean+/−10%, unless otherwise stated. Also, the terms “have,” “include,” “contain,” and similar terms are defined to mean “comprising” unless specifically stated otherwise. Furthermore, the terminology used in the specification provided above is hereby defined to include similar and/or equivalent terms, and/or alternative embodiments that would be considered obvious to one skilled in the art given the teachings of the present patent application. While the invention has been described with reference to at least one particular embodiment, it is to be clearly understood that the invention is not limited to these embodiments, but rather the scope of the invention is defined by claims made to the invention.

Claims

1. A comforter comprising: a first fabric sheet and a second fabric sheet, each comprising a knit cover layer formed from a base yarn, and knitted into this base layer is a fibrous fluffy yarn in such a manner that a looped pile results, and wherein the looped pile is then sheared to create a cut pile nap;wherein the first and second fabric sheets are stitched together around a perimeter with perimeter stitching, to contain a fill material between the first and second fabric sheets and within the perimeter stitching; andwherein the first and second fabric sheets are also stitched together via lateral stitching that extends laterally at least partially across the comforter at spaced longitudinal intervals, so that the first and second fabric sheets are connected via the longitudinal stitching and movement of the fill material is constrained.

2. The comforter of claim 1, wherein the base yarn is elastic.

3. The comforter of claim 1, wherein the base yarn is polybutylene tetraphthalate.

4. The comforter of claim 1, wherein the fill material is hollow siliconized polyester fibers.