FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
[See section 10, Rule 13]
TITLE OF THE INVENTION
IMPROVED WOVEN FABRICS FOR HOME TEXTILES
APPLICANT:
WELSPUN LIVING LIMITED, an Indian Company, having address at Welspun House, 6th Floor, Kamala City, Senapati Bapat Marg, Lower Parel (W), Mumbai – 400013, Maharashtra, India;
Preamble to the description:
The following specification particularly describes the invention and the manner in which it is to be performed:

TECHNICAL FIELD
[0001] The present disclosure is direct to an improved woven fabrics for home textile applications.
BACKGROUND
[0002] Conventional satin fabrics have a long floats of warp yarns on the face with longer floats of weft yarns on the back of the fabric. The result is more warp coverage on the face of the fabric while more weft coverage on the back of the fabric. Cover factor has been defined as the extent of coverage of yarns in the fabric. It is a number that indicates the extent to which the area of a fabric is covered by one set of yarn/yarns. Essentially, the cover factor shows how much of the fabric in the direction of warp yarns is filled in by the weft yarns and vice versa. For any woven fabric, there are two cover factors: a warp cover factor and a weft cover factor. Under the cotton system, the cover factor is the ratio of the number of yarns per inch to the square root of the cotton yarn count. The warp cover factor (WCF) is therefore the ends per inch (EPI) divided by the square root of the warp yarn count. The weft cover factor (PCF) is the picks per inch (PPI) divided by the square root of the weft yarn count. The overall cloth cover factor is given by the following equation:
[
0003] 𝑪𝒐𝒗𝒆𝒓 𝑭𝒂𝒄𝒕𝒐𝒓=(𝑾𝑪𝑭+𝑷𝑪𝑭)−(𝑾𝑪𝑭×𝑷𝑪𝑭𝟐𝟖)

[0004] The yarn diameter or yarn count therefore affects the fractional cover factor. Weave designs and number of yarns drawn through a dent in a reed during weaving also affects cover factor. A conventional 4 up 1 down satin is warp faced is also called 5 end satin. It means 5 end & 5 picks in a basic repeat. Commercially fabrics available in conventional warp faced 5 end satin has warp cover factor in the range of 16 to 27 while the weft cover factor ranges of 9 to 15. Thus, when synthetic yarns in used in the weft, the back has a stiff and harsh synthetic hand-feel while the face, when warp yarns are natural fibers such as cottons, is generally softer for front side. This limits the utility of using satin weaves for certain constructions, especially in situations where a synthetic weft yarns and natural fiber warp yarns are advantageous, such as home textile applications like sheeting fabrics.
SUMMARY
[0005] There is a need for an improved satin fabrics with better softness and hand-feel on both

sides of the fabric while also providing for the improved strength and durability. Accordingly, an embodiment of the present disclosure is a woven fabric with high warp coverage on the face and the back of the fabric so that the weft yarns are mostly positioned between the face and back of the fabric. The woven fabric includes a first set of warp yarns, a second set of warp yarns, and a set of weft yarns. The set of weft yarns being interwoven with the first set of warp yarns and the second set of warp yarns so that 1) the first set of warp yarns define the face of the woven fabric, and 2) the second set of warp yarns define the back of the woven fabric and are opposite the first set of warp yarns so that the set of weft yarns are interposed substantially in between the face of the woven fabric and the back of the woven fabric. The face and the back each have a warp cover factor that is greater than a weft cover factor.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The foregoing summary, as well as the following detailed description of illustrative embodiments of the present application, will be better understood when read in conjunction with the appended drawings. For the purposes of illustrating the present application, there is shown in the drawings illustrative embodiments of the disclosure. It should be understood, however, that the application is not limited to the precise arrangements and instrumentalities shown.
[0007] Figure 1 is a schematic view of a technical face of a woven fabric according to an embodiment of the present disclosure;
[0008] Figure 2 is a schematic view of the technical back of the woven fabric shown in Figure 1;
[0009] Figure 3 is schematic cross sectional view of the woven fabric taken along line 2-2 in Figure 1;
[00010] Figure 4 is schematic cross sectional view of the woven fabric shown in
Figures 1-3 illustrating how the first set of warps overly the second set of warp yarns in the;
[00011] Figure 5 is a peg plan of the woven fabric shown in Figures 1 to 4, according
to an embodiment of the present disclosure;
[00012] Figure 6 is a drawing plan of the woven fabric shown in Figures 1 to 3,
according to an embodiment of the present disclosure;

[00013] Figure 7 is a schematic view of a technical face of a woven fabric according
to an embodiment of the present disclosure;
[00014] Figure 8 is schematic sectional view of the woven fabric shown in in Figure
7 illustrating how the first set of warps overly the second set of warp yarns in woven fabric shown in Figures 1-3;
[00015] Figure 9 is a peg plan of the woven fabric shown in Figures 7 and 8,
according to an embodiment of the present disclosure; and
[00016] Figure 10 is a drawing plan of the woven fabric shown in Figures 7 and 8,
according to an embodiment of the present disclosure.
[00017] DETAILED DESCRIPTION
[00018] Embodiments of the present disclosure include a woven fabric 10 with a
construction that places a set of warp yarns along the face and a set of warp yarns on back and aligned with the set of warp yarns on the face, but with weft yarns interposed in between the two sets of warp yarns, in a given design repeat. The design may employ satin (Figures 1-4) and twill (Figures 7 and 8) weave constructions so that a warp coverage is greater than weft yarn coverage on the face and the back.
[00019] The woven constructions described herein permits softer, natural fiber or
blends of natural and regenerated cellulose fiber yarns to be used in warp and forms the face and back of the fabric while synthetic yarns can be used in weft yarns and forms the middle of the fabric between the face and the back. The result is a desirable construction suitable for home textile, such as bedding, curtains and the like, or apparel. For example, embodiments of the present include bedding or bedroom articles including, but not limited to flat sheets, fitted sheets, pillowcases, shams, euro shams, comforters, duvets, bed-skirt, blankets, mattress covers, and the like. One embodiment is a coordinated bedding system comprising a plurality of system components. The system components include at least two of a flat sheet, a fitted sheet, a pillow case, a sham, a comforter, a duvet, a bed-skirt, and a blanket. Furthermore, embodiments of the present disclosure include garments, such as tops, bottoms, and outerwear and the like. Each system components includes the woven fabric prepared in accordance with the present disclosure.
[00020] Turning to Figures 1-4, an embodiment of the present disclosure is a woven
fabric 10 having warp yarns 20 and weft yarns 40 interwoven with the warp yarns 20 to define

the woven fabric 10. The woven fabric 10 includes a face 12, which is shown in Figure 1, and a back 14 opposite the face 12 along direction 8, which is shown in Figures 2 and 3. The warp yarns 20 extend along a warp or longitudinal direction 6 and the weft yarn extends along weft direction 4 (or lateral or cross direction). The woven fabric 10 is designed such that the predominate portion of the face 12 includes natural fiber yarns, while a predominate portion of the back 14 includes exposed warp yarns that also include natural fiber yarns. Furthermore, the weft yarns may be synthetic yarns as further described below. The woven fabric 110 shown in Figures 7-10 is a version of the embodiments described herein and common reference numbers are used to identify common features between woven fabric 10 and woven fabric 110.
[00021] The woven fabrics 10,110 has disclosed herein may also be considered
multilayered fabrics formed from a single or common warp. In this manner, the woven fabrics 10, 110 may include an upper layer defining the face 12 formed from a first set of warp yarns 22 and a set of weft yarns 40. The woven fabrics 10, 110 may also have a lower layer defining the back 14 formed from a second set of warp yarns 24 and the set of weft yarns 40. In this way, the upper layer and the lower layer are integrated to define the woven fabric 10, 110 and the set of weft yarns 40 are interposed substantially between the face 12 of the woven fabric and the back 14 of the woven fabric such that face 12 and the back 14 are predominantly the first and second sets of warp yarns 22, 24. As described above, the first and second set of warp yarns 22, 24 include spun yarns formed from natural fibers and the set of weft yarns 40 include yarns formed from synthetic fibers.
[00022] Continuing with Figures 1-4, for a given design repeat of the woven fabric 10,
the warp yarns 20 include a first set of warp yarns 22 and a second set of warp yarns 24. The set weft yarns 40 are interwoven with the first set of warp yarns 22 and the second set of warp yarns 24 so that; 1) the first set of warp yarns 22 define the face 12 of the woven fabric 10; 2) the second set of warp yarns 24 define the back 14 of the woven fabric 10 and that are substantially opposite the first set of warp yarns 22; and 3) the set of weft yarns are interposed substantially in between the face 12 of the woven fabric 10 and the back 14 of the woven fabric 10. In this manner, the face 12 and the back 14 each have a warp cover factor that is greater than a weft cover factor.
[00023] The woven fabric 10 may be defined by a number of different woven structures
with substantial end floats. Exemplary woven structures include, but are not limited to satin weaves and twill weaves. The fabric 10 shown in Figures 1-3 is a satin weave construction. Further below, a 2/1 twill weave construction is described and shown in Figures 7-10.

[00024] As shown in Figures 1-3, the woven fabric 10 has a first set of warp yarns 22
and a second set of warp yarns 24. The woven fabric 10 as illustrated is 4 × 1 or 5 end satin construction. In this design, there are at least five weft yarns per repeat and 10 warp yarns per repeat. Constructed this way, the first set of warp yarns and the set of weft yarns form a satin weave construction on the face 12 and the second set of warp yarns and the weft yarns form a satin weave construction on the back 14. More specifically, as illustrated, the satin weave construction on the face 12 is a five end satin (e.g. 4 × 1 satin) and the satin weave construction on the back 14 is a five end satin (e.g. 4 × 1 satin). Accordingly, as shown in the peg plan of Figure 5 and the drawing plan of Figure 6, the first of warp yearns 22 are drawn through the drawing frame and reed so that they comprise a substantial the face 12 of the woven fabric. The second set of warp yarns 24 are drawn through the drawing frame and read so that they comprise a substantial amount of the back of the woven fabric 10. Furthermore, after the fabric formation, when the fabric is in a relaxed state, the first set of warp yarns 22 are aligned with and opposite the second set of warp yarns 24 with the weft yarns positioned substantially between two sets of warp yarns 22, 24. Constructed this way, the first and second set of warp yarns 22 and 24 are generally aligned with each other and opposite each other. For example, a first yarn of the first set of warp yarns may substantially overlie a first yarn of the second set of warp yarns. Furthermore, a second yarn of the first set of warp yarns 22 my substantially overlie a second yarn of the second set of warp yarns 24. While perfect alignment of the warp yarns may not occur, due to yarn settling and contraction, the two set of warp yarns are substantially aligned.
[00025] In the example shown in Figures 1-4, the woven fabric has a satin weave
construction. For satin weave construction, there may be five (5) warp yarns in the first set of
warp yarns 22 and five (5) warp yarns in the second set of warp yarns 24, in a given design
repeat. In the example woven fabric 110 shown in Figures 7-10, a twill weave design is
formed on the face 12 and back 14. Common reference numbers are used to illustrate common features between woven fabric 10 and woven fabric 110 shown in the Figures. More specifically, in Figures 7-10, the first set of warp yarns and the set of weft yarns form a twill weave construction on the face and the second set of warp yarns the set of weft yarns form a twill weave construction on the back. In some example, the twill weave construction on the face is a 2 × 1 twill, and the twill weave construction on the back is a 2 × 1 twill. In some example, the twill weave construction on the face is a 3 × 1 twill, and the twill weave construction on the back is a 3 × 1 twill.
[00026] Accordingly, for the different designs disclosed in the present application, in

a single design repeat, the first set of warp yarns is between three warp yarns and five warp yarns, the second set of warp yarns is between three warp yarns and five warp yarns; and the set of weft yarns is between three warp yarns and five weft yarns.
[00027] The woven fabrics as disclosed herein have unique cover factors due to their
novel constructions. In one example, a warp cover factor of the face and the back is between 22 to 29 and a weft cover factor of the face and the back is greater than 6. Furthermore, the weft cover factor of the face and the back is less than 16. The total cover factor can range between 37 and 42. Another way to consider yarn coverage is a percentage of yarns that occupy the area of the face or back of the fabric. In the present embodiments, a warp coverage of warp yarn on the face is at least 80% and a warp coverage on the back is at least 80 %.
[00028] During weaving, whether a satin type design or a twill type design, the fabric
formation phase can utilize different weft insertion techniques, includes air-jet, rapier, or projectile type weft insertion techniques. In each weft insertion event, one or more weft yarns may be inserted through the shed. In one example, weft yarns may be co-inserted through the shed. In one example, the warp yarns are arranged to define a warp end density between about 50 warp ends per inch (EPI) and about 500 warp ends per inch (EPI). The weft yarns are arranged to define a weft density between about 10 picks per inch (PPI) and about 1200 picks per inch (PPI). Furthermore, the woven fabric can be constructed so define a thread count between 150 and 1700). Furthermore, the woven fabric can be constructed so define a thread count between 250 and 2400.
[00029] As described above, the face and back are substantially composed of warp
yarns 20 from the natural fibers, while the weft yarns 40 are formed synthetic fibers and substantially located between the face and the back.
[00030] The warp yarns 20 may comprise a spun yarn of natural fibers, preferably
cotton. For example, the weft yarns can be ring spun yarns, open end yarns, rotor spun yarns, vortex spun yarns, core spun yarns, jet spun yarns, or compact spun yarns or any other suitable staple fiber spinning system. In another embodiment, the warp yarns can be Hygrocotton ® brand yarns marketed by Welspun India Limited. Furthermore, yarns can be formed as disclosed in U.S. Patent No. 8,833,075, entitled “Hygro Materials for Use In Making Yarns And Fabrics,” (the 075 patent). The 075 patent is incorporated by reference into present disclosure. Preferably, the warp yarn 20 is a ring spun yarn. The weft yarn 20 can, however, be any type of spun yarn structure.
[00031] While the warp yarn 20 is primarily cotton, in certain alternative

embodiments, the warp yarn 20 can include cotton fibers blended with other natural fibers. In such an example, the natural fibers could include linen, flax, bamboo, hemp, raime, nettle wool, silk, and the like. In some cases, the warp yarn may include blends of natural synthetic fibers, such as regenerated cellulose, with substantially more natural fibers than synthetic fibers. In such example, the synthetic fibers may comprise those fibers that result in fabric structures with good hand, drape, and softness. Such synthetic fibers include rayon fibers (e.g. Modal, Lyocell) or thermoplastic fibers, such as polyethylene terephthalate (PET) fiber, nylon, polylactic acid (PLA) fiber, polypropylene (PP) fibers, polyamide fibers, and microfiber staple fibers. In another embodiment, the fiber could be made from bio based polymer. In one example, the weft yarns may be thermoplastic fibers in filament form or staple yarns. In other example, the cross-section of thermoplastic fibers may be circular, trilobal, star shape, quardilobe, 4 or 6 channel cross-section like coolmax fiber or any other suitable shape in solid or in hollow. The hollowness will depends upon the property required.
[00032] The warp yarns 20 have a range of counts for the yarn types and fibers as
described above. For instance, the warp yarn 20 can have count in a range between about 20 Ne (268.5 denier) to about 140 Ne (38.4 denier). In one example, the warp yarn 20 can have count in a range between about 20 Ne (268.5 denier). In one example, the warp yarn 20 can have count in a range between about 30 Ne (177 denier). In one example, the warp yarn 20 can have count in a range between about 40 Ne (133 denier). In another example, the warp yarn 20 has a count of about 60 Ne (88.6 denier). In another example, the warp yarn 20 has a count of about 70 Ne (75.9 denier). In another example, the warp yarn 20 has a count of about 80 Ne (66.4 denier). In one example, the warp yarn is 2-ply yarn. In another example, the warp yarn is a 3-ply yarn. In another example, the warp yarn is a 4-ply yarn or more.
[00033] The weft yarns 40 are synthetic staple yarns or synthetic continuous filament
yarns. The weft yarns when spun synthetic yarns from staple fibers may include PA (Nylon) staple fibers, PET staple fibers, PLA staple fibers, PP staple fibers, or other fibers. The continuous filament yarns may include PA (Nylon) filaments, PET filaments, PLA filaments, PP filaments, or other filaments. The yarns may be made from recycled polymers, such as recycled nylon fibers and recycled PET fibers. With filament or staple fibers, the weft yarns could be synthetic fibers or filaments with different component infused therein. The fibers in such yarns can have round cross-sections, tri-lobal, muti-lobal, square, oval, hollow core. Such fibers could also be dope dyed as needed.
[00034] The weft yarns 40 can have a range of yarn counts. For instance, in one
example, the weft yarn 40 can have count in a range between about 50 denier (106 Ne) to

about 255 denier (21 Ne). As further detailed below, embodiments of the present disclosure include weft yarn 40 dyed prior to fabric formation. The yarns could be dope dyed. For example, the weft yarn 40 can be a dope-dyed, continuous filament yarn. In another example, the weft yarn 40 can be dyed using a disperse dyes via package dyeing process (not shown).
[00035] The described features, advantages and characteristics of exemplary
embodiments may be combined in any suitable manner in one or more embodiments. One skilled in the art will recognize, in light of the description herein, that the exemplary embodiments can be practiced without one or more of the specific features or advantages of a particular embodiment. In other instances, additional features and advantages may be recognized in certain embodiments that may not be present in all embodiments of the present disclosure.
[00036] While the disclosure is described herein, using a limited number of
embodiments, these specific embodiments are not intended to limit the scope of the disclosure as otherwise described and claimed herein. The precise arrangement of various elements and order of the steps of articles and methods described herein are not to be considered limiting. For instance, although the steps of the methods are described with reference to sequential series of reference signs and progression of the blocks in the figures, the method can be implemented in an order as desired.

WE CLAIM:
1. A woven fabric having a face and a back that is opposite the face, the woven fabric
comprising:
a first set of warp yarns;
a second set of warp yarns, wherein the first and second set of warp yarns include spun yarns formed from natural fibers or a combination of natural fibers and synthetic fibers; and
a set of weft yarns that include yarns formed from synthetic fibers, the set of weft yarns being interwoven with the first set of warp yarns and the second set of warp yarns so that 1) the first set of warp yarns define the face of the woven fabric, 2) the second set of warp yarns define the back of the woven fabric and are opposite the first set of warp yarns so that the set of weft yarns are interposed substantially in between the face of the woven fabric and the back of the woven fabric, wherein the face and the back each have a warp cover factor that is greater than a weft cover factor, giving rise to a soft feel and improved durability.
2. The woven fabric according to claim 1, wherein a warp cover factor of the face and the back is between 22 to 29 and a weft cover factor of the face and the back is greater than 6.
3. The woven fabric according to claim 2, wherein the weft cover factor of the face and the back is less than 16.
4. The woven fabric according to claim 1, wherein a warp coverage of warp yarn on the face is at least 80% and a warp coverage on the back is at least 80 %.
5. The woven fabric according to claim 1, wherein the first set of warp yarns and the set of weft yarns form a satin weave construction on the face and the second set of warp yarns the set of weft yarns form a satin weave construction on the back.
6. The woven fabric according to claim 5, wherein satin weave construction on the face of is five end satin, wherein the satin weave construction on the back five end satin.
7. The woven fabric according to claim 1, wherein the first set of warp yarns and the set of weft yarns form a twill weave construction on the face and the second set of warp yarns the set of weft yarns form a twill weave construction on the back.
8. The woven fabric according to claim 7, wherein the twill weave construction on the

face of is a 2 × 1 twill, and wherein the twill weave construction on the back of is a 2 ×1 twill.
9. The woven fabric according to claim 1, wherein, in a single design repeat:
a. the first set of warp yarns is between three warp yarns and five warp yarns;
b. the second set of warp yarns is between three warp yarns and five warp yarns;
and
c. the set of weft yarns is between three warp yarns and five weft yarns.
10. The woven fabric according to claim 1, wherein the warps ends per inch (EPI) is between 50 EPI and 500 EPI, and weft picks per inch (PPI) is between 10 PPI and 1200,wherein the thread count is between 150 and 1700, and wherein count of the first and second set of warps yarns is between 20 Ne and 140 Ne.
11. A woven fabric having a face and a back, the wove n fabric comprising:
an upper layer defining the face formed from a first set of warp yarns and a set of weft yarns; and
a lower layer defining the back formed from a second set of warp yarns and the set of weft yarns, wherein the upper layer and the lower layer are integrated to define the woven fabric and the set of weft yarns are interposed substantially between the face of the woven fabric and the back of the woven fabric such that face and the back are predominantly the first and second sets of warp yarns;
wherein the first and second set of warp yarns include spun yarns formed from natural fibers and the set of weft yarns include yarns formed from synthetic fibers.
12. The woven fabric according to claim 11, wherein a warp cover factor of the face and the back is between 22 to 29 and a weft cover factor of the face and the back is greater than 6.
13. The woven fabric according to claim 11, wherein the weft cover factor of the face and the back is less than 16.
14. The woven fabric according to claim 11, wherein a warp coverage of warp yarn on the face is at least 80% and a warp coverage on the back is at least 80 %.
15. The woven fabric according to claim 11, wherein the first set of warp yarns and the set of weft yarns form a satin weave construction on the face and the second set of warp yarns the set of weft yarns form a satin weave construction on the back.

16. The woven fabric according to claim 15, wherein satin weave construction on the face of is a five end satin, wherein the satin weave construction on the back is a five end satin.
17. The woven fabric according to claim 11, wherein the first set of warp yarns and the set of weft yarns form a twill weave construction on the face and the second set of warp yarns the set of weft yarns form a twill weave construction on the back.
18. The woven fabric according to claim 17, wherein the twill weave construction on the face of is a 2 × 1 twill, and wherein the twill weave construction on the back of is a 2 × 1 twill.
19. The woven fabric according to claim 11, wherein, in a single design repeat:
a. the first set of warp yarns is between three warp yarns and five warp yarns;
b. the second set of warp yarns is between three warp yarns and five warp yarns;
and
c. the set of weft yarns is between three warp yarns and five weft yarns.
20. The woven fabric according to claim 11, wherein the warps ends per inch (EPI) is
between 50 EPI and 300 EPI, and weft picks per inch (PPI) is between 10 PPI and 100 PPI is
always less than the EPI, wherein the thread count is between 150 and 1700, wherein count of
the first and second set of warps yarns is between 20 Ne and 140 Ne.