SHEETING FABRIC IN 100% COTTON AND A PROCESS FOR ITS PRODUCTION
FIELD OF THE INVENTION
The present invention relates to sheeting fabrics of 100% cotton which provide good feel, and have improved tensile and tearing strength, and a method for their production. The invention especially relates to three varieties of sheeting fabrics classified based on their thread counts (TC), termed as 600 TC, 800 TC and 1000 TC. These fabrics are made using exclusive quality of raw material, employing a process which is eco-friendly.
BACKGROUND OF THE INVENTION Sheeting fabrics are most often used to make bed linens but its light weight, easy care, versatility and due to their larger widths, they are used as quilt backs, linings, drapery linings, tablecloths, as test garments and for any other purpose for which extra wide cloths are required. Fabrics of 600, 800 & 1000 thread count are accepted as the most lustrous sheeting fabric globally.
Recently, 100% cotton based sheeting fabrics are preferred over synthetic and semi-synthetic fabrics in view of the comfort rendered by them and their other advantages such as being more absorbent, breathable, being eco-friendly, etc. In view of this there is a constant need for producing 100% cotton sheeting fabrics with the preferred advantages cited above. While the desired "feel" for bed linens is subjective, it is commonly accepted that the "feel" of cotton bedding is preferred by most persons. In addition to its desirable "feel" factor, cotton has an absorbency that tends to keep a person's skin dry.
Sheets made of 100%) cotton are generally regarded as providing the greatest comfort and absorbency. Nevertheless, the durability of the sheet is an important consideration, especially in regard to commercial applications, where the sheet may be subjected to high temperatures and harsh chemicals during laundering and ironing. For example, the life cycle of a 100%) cotton sheet is approximately 50 to 60 industrial launderings and ironings. Since many applications require that the sheets be changed every day, such as in ^ hospitals and hotels, the replacement cost of sheets is a significant expense.

There have been many fabrics in which the durability and other desirable characteristics of polyester have been combined with the desired "feel" and other characteristics of cotton through the use of yarns spun from polyester and cotton staples. Sheeting fabrics employing spun cotton/polyester yarns are taught in US Patent Nos. US4578306 and US4724183. In the '306 and '183 patents the warp yarns are formed of a blend of natural and synthetic material (cotton/polyester) and the filling yarns (also referenced as weft yarns) are formed of natural fibers (cotton).
More specifically, US4578306 teaches a preferred fabric in having a total yarn count of 192 yarns/sq. in. and 110 warp/82 filling. Long staple combed cotton is employed in both the warp and filling yarns. The cotton content of the sheeting material is 70% and the plain weave is such that the surface area comprises approximately 80% cotton by weight. US4724183 patent teaches a fabric with a total yarn count of 143 yarns/sq. in. and 75 warp/68 filling. The cotton used is carded cotton, with the cotton content of the fabric being 75% by weight. Again the surface area of the fabric comprised approximately 80% cotton.
US4191221 discloses a sheeting fabric which is formed of warp and filling yarns of corespun construction with each of the corespun warp and filling yarns having a core portion of multifilament polyester and a sheath portion formed of cellulosic fibers helically wrapped about the multifilament polyester core portion to substantially surround and encase the multifilament polyester core.
US5495874 discloses a woven fabric useful for sheeting having cotton warp yarns and continuous filament, textured, polyester filling (weft) yarns. The product has a warp-to-fill ratio of from 1.6:1 to 2.2:1. Despite having a relatively high warp-to-fill yarn ratio, the fabric is substantially weaker in the warp direction than the filling direction, with reported tensile strength values of 57.4 lbs. and 99.0 lbs., respectively. The relatively low tensile strength in the warp direction represents a "weak link" in the fabric construction, and likely point of failure during the life cycle of a sheet made from the fabric.

US 8186390 discloses a woven textile fabric for use as a bed sheet having spun cotton warp yarns and continuous multi-filament weft yarns, to provide a total yarn count of from 170 to 215, and wherein the construction of the fabric balances the tensile strength of the fabric in the warp and weft direction, to provide a tensile strength in one direction of the fabric that is at least 80% of the tensile strength in the cross direction.
It is also to be recognized that there are many other fabric constructions that incorporate various combinations of cotton and polyester yarns, as well yarns formed of other natural materials, such as silk, and other synthetic materials such as nylon. It is also to be recognized that these various forms of yarns have been used as both warp yarns and filling yarns in various combinations.
There remains a need in the industry for a 100 % cotton sheeting fabric having the comfort of cotton fiber along with the strength and durability as provided by a polyester fiber. Further, there is a need for a sheeting fabric having a relatively high tensile strength in both the warp and filling direction. Still further, there is a need for a sheeting fabric having a tensile strength in the warp and filling direction that is balanced, to avoid over-engineering the fabric in one direction, at the expense of the tensile strength in the cross direction.
The present invention provides an environment friendly method and concentrates more on producing sheeting fabrics which are 100% cotton and with 600 TC, 800 TC and 1000 TC. Though it is known in the art that the fineness of the fabric increases with its thread count, the durability of the fabric in terms of improved tensile strength and tearing strength is not achieved. The sheeting fabric according to the present invention has an improved tensile strength and tearing strength.
Further, generally only 200 to 500 TC fabrics are preferred as sheeting fabrics as they are considered to be of lightweight. But these lower TC fabrics of 200 to 500 TCs are made of coarser count yarn compared to higher TC fabrics. Usage of finer yarns is to facilitate
j| hassle free weaving of higher TC fabrics. But the finer threads according to the invention
*&a aid in the packing of more number of threads into the fabrics.

In the conventional manufacturing process, mechanically plied 90/1 Ne yarn was used as the weft. This mechanically plied yarn has a tendency to deviate and may over lap each other after woven into the fabric. This causes irregular spacing between the yarn, and leads to irregular interlacement of warp threads, resulting in non-uniform appearance of fabric surface and lack of luster.
The present inventors have proposed the use of chemically laminated threads to ensure uniform spacing of the threads in weft way which helps to retain a uniform structure of warp interlacement and hence provides an improved appearance and luster and also avoids the chances of two threads overlapping each other after being woven in to the fabric.
The present invention provides sheeting fabrics of 100% cotton which provide maximum comfort and a method of manufacturing them. The process described in the present invention can be easily scaled up and is cost effective. The method used for manufacturing these sheeting fabrics is eco-friendly. In view of this they would not render any detrimental effect to both the manufacturer or to the end user.
SUMMARY OF THE INVENTION
In accordance with the purposes of the present invention, as embodied and broadly described herein, the present invention provides sheeting fabrics of 100% cotton which provide maximum comfort, and a novel method for manufacturing them.
In one aspect, the present invention provides a 100 % cotton fabric sheeting with improved feel and improved tensile and tearing strength said sheeting being formed using chemically laminated threads, wherein the weft and warp yarns are comprised of two or more threads of yarn bonded together with the help of an adhesive. Further, the chemical lamination of the yarn using an adhesive distinguishes the process of the present invention from the known prior art processes.

A further aspect of the present invention provides a process to produce sheeting fabrics that are of 100% cotton with improved feel and improved tensile and tearing strength comprising the steps of:
. selection of raw material,
. spinning;
. weaving; and
. Finishing of the product.
Thus, the present invention comprises a combination of features and advantages which enable it to overcome various problems of prior art methods. Other features and advantages of the present invention will become apparent as the following detailed description proceeds or may be learned by practice of the invention. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention.
BRIEF DESCRIPTION OF DRAWINGS The foregoing summary, as well as the following detailed description of the invention will be better understood when read in conjunction with the appended drawings. For the purpose of assisting in the explanation of the invention, there are shown in the drawings embodiments which are presently preferred and considered illustrative. It should be understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown therein.
Fig. 1: is diagrammatic representation to show the warp yarn placement in a fabric which is mechanically plied, versus one which is chemically laminated.
Fig. 2: is diagrammatic representation to show the weft yarn placement in a fabric which is mechanically plied, versus one which is chemically laminated
DETAILED DESCRIPTION OF THE INVENTION In describing and claiming the invention, the following terminology will be used in accordance with the definitions set forth below. Unless defined otherwise, all technical

and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, the preferred methods and materials are described herein.
As used herein, each of the following terms has the meaning associated with it in this section. Specific and preferred values listed below for individual process parameters, substituents, and ranges are for illustration only; they do not exclude other defined values or other values falling within the preferred defined ranges.
As used herein, the singular forms "a," "an," and "the" include plural reference unless the context clearly dictates otherwise.
The terms "preferred" and "preferably" refer to embodiments of the invention that may afford certain benefits, under certain circumstances. However, other embodiments may also be preferred, under the same or other circumstances. Furthermore, the recitation of one or more preferred embodiments does not imply that other embodiments are not useful, and is not intended to exclude other embodiments from the scope of the invention.
When the term "about" is used in describing a value or an endpoint of a range, the disclosure should be understood to include both the specific value and end-point referred to.
As used herein the terms "comprises", "comprising", "includes", "including", "containing", "characterized by", "having" or any other variation thereof, are intended to cover a non-exclusive inclusion.
As used herein, "Ne" refers to English cotton yarn number. It is based on the number 840 yard hanks in one pound of yarn, so a cotton count of'2' would mean 1680 yards of yarn weigh 1 pound.

As used herein the term "fabric" includes any cloth made from yarn or fibres by weaving, knitting, felting, etc. The fabric may comprise a plurality of layers.
As used herein, the term "sheeting fabric" is intended to mean a fabric which is used to make bed linens, quilt backs, linen and other items.
As used herein, the term "warp yarn" or end is intended to mean the set of lengthwise yarns that are held in tension on a frame or loom during weaving the cloth. Warp is the set of yarns that runs lengthwise and parallel to the selvage, and is interwoven with the fill. The sheet of yarns wound together on a beam for the purpose of weaving or warm knitting. Warping is the operation of winding yarns onto a beam, usually in preparation for slashing, weaving or warp knitting.
As used herein, the term "weft yarn" is intended to mean the horizontal yarns in a cloth which run selvage to selvage across the fabric. The yarn that is inserted over-and-under the warp threads during weaving the cloth.
As used herein, the term "tearing strength" is intended to mean the property of the fabric that is measured by the force required to tear it. It is measured in terms of pounds (lbs).
As used herein, the term "tensile strength" refers to the strength exhibited by a fabric subjected to tension, as distinct from torsion, compression or shear. It is measured in terms of pounds (lbs).
As used herein the term "aero finish" intends to mean a process using air to "thrash" the fabric until soft to the hand.
As used herein, the term "thread count" or threads per inch (TPI) is a measure of the coarseness or fineness of fabric. It is measured by counting the number of threads contained in one square inch of fabric or one square centimeter, including both the length (warp) and width (weft) threads. The thread count is the number of threads counted along two sides (up and across) of the square inch, added together.

As used herein, the term "ends per inch" (EPI or e.p.i.) is the number of warp threads per inch of woven fabric. In general, the higher the ends per inch, the finer the fabric is.
As used herein, the term "picks per inch" (PPI or p.p.i.) intends to mean the number of »weft threads per inch of woven fabric. A pick is a single weft thread, hence the term. In
i
> general, the higher the picks per inch, the finer the fabric is.
J
) As used herein, the term "twists per inch or turns per inch" intends to mean a measure of how much twist a yarn has, and can be calculated by counting the number of twists in an inch of yarn.
As used herein, the term "fiber length" intends to mean the average length of the longer one-half of the fibers (upper half mean length)". Typical lengths of Upland cottons might range from 0.79 to 1.36in.
As used herein, the term "compression resilience" intends to mean the power or ability to return to the original form, position, etc., after being compressed.
As used herein, the term "singe" intends to mean a slight scorching, burn or treatment with flame. This may be due to an accident, such as scorching one's hair when lighting a gas fire, or a deliberate method of treatment or removal of hair or other fibres.
In one aspect, the present invention provides a 100 % cotton fabric sheeting with improved feel and improved tensile and tearing strength said sheeting being formed using chemically laminated threads, wherein the weft and warp yarns are comprised of two or more threads of yarn bonded together with the help of an adhesive.
In an embodiment, the present invention relates to 600 TC, 800 TC and 1000 TC based sheeting fabrics which are comfortable and possess all the desired luxurious qualities like improved feel, tensile strength, and tearing strength.

The fabric of the present invention has a minimum tensile strength in the warp direction of 50 lbs., preferably a minimum of 60 lbs., and a minimum tensile strength in the weft direction of 40 lbs., preferably a minimum of 50 lbs. In one embodiment of the invention,
i" the fabric is constructed to balance the tensile strength in the warp and weft direction.
s I
>
I Accordingly, the tensile strength in any direction may be at least 50%, in particular at
least 60%, of the tensile strength in the cross direction. For example, the tensile strength
of the fabric in the warp direction is at least 50% of the tensile strength of the fabric in the
weft direction.
The fabric has minimum tear strength in the warp direction of 10 lbs., in particular 12 lbs, and a minimum tear strength in the weft direction of 10 lbs, in particular 15 lbs.
Tensile strength was determined according to ASTM D5034 Standard Test Method for Breaking Strength and Elongation of Textile Fabrics (Grab Test) and tear strength was determined according to ASTM D1424 Standard Test Method for Tearing Strength of Fabrics.
Another aspect of the present invention provides a process to produce sheeting fabrics that are of 100% cotton with improved feel and improved tensile and tearing strength comprising the steps of:
a) selection of raw material,
b) spinning;
c) weaving; and
d) Finishing of the product.
The cotton yarn used for the purposes of the present invention may have a yarn count from Ne 20 to about Ne 400, or from about Ne 40 to Ne 250.
f As the present invention pertains to sheeting fabric of cotton sheets, the raw material is p? selected from cotton which is longer and stronger. Generally, a blend of selected long !T^ staple cotton fibers are used, in which more than 30% of the fibers are longer than the

Egyptian cotton span length and stronger than any other cotton varieties. The finer yarns according to the present invention have several special features as mentioned below:
• Less hairy
• Excellent uniformity of the texture
• Good strength characteristics
• Extremely lustrous
• Rich to handle
Further, the selected cotton varieties have the maximum moisture regain characteristics. This induces a good absorption property on the fabric which helps to reduce the discomfort of sweating while sleeping. The cotton fibers also have more amorphous region than crystalline region. This contributes to the good color brilliance, feel and finish of the sheeting fabric of the present invention. Therefore the selection of raw material plays a major role in achieving the object of the invention revealed above.
Fiber quality index (FQI) and the fiber strength of the yarn are major criteria to obtain the sheeting fabric with the desired qualities. According to the present invention, the fiber quality index (FQI) for warp yarn should be from 116 to 125 g/tex inclusive and that of the weft yarn should be from 89 to 144 g/tex inclusive. The invention necessitates that the fiber strength is from 28 g/tex to 34 g/tex inclusive for Warp and 27g/tex to 34g/tex inclusive for weft.
According to the present invention for manufacturing the 600 TC sheeting fabric the Fiber quality index (FQI) for warp yarn should be 116 and that of the weft yarn should be from 89. The Fiber strength should be 28.6 g/tex for Warp and 27g/tex for weft. For manufacturing the 800TC sheeting fabric the Fiber quality index ( FQI ) for warp yarn should be 116 and that of the weft yarn should be 125.5. The Fiber strength should be 29.9 g/tex for Warp and 33.5g/tex for weft. For manufacturing a 1000 TC sheeting fabric according to the present invention, the Fiber quality index ( FQI) for warp yarn is 125 l and weft yarn is 143.9. The Fiber strength is 33.5 g/tex for Warp and 31.9g/tex for weft.

The fiber length provided in the table below also plays a major role in producing the sheeting fabric of the present invention.
The selected cotton varieties have the maximum moisture regain characteristics. This will induce a good absorption property on the fabric which helps to reduce the discomfort of sweating while sleeping.
The first step in the manufacture of a sheeting fabric is the spinning of the yarn. Fiber blending or mixing are a part of the spinning process. In this stage the cotton is mixed to maintain uniformity of fiber quality. This can be carried out using bale breakers and any possibility of contamination is eliminated by the usage of contamination cleaner.
Following mixing the cotton is introduced into the blow room to remove the impurities and the lumps in the cotton and from there they are subjected to Carding. Before the raw material is converted into yarn, the remaining impurities are removed, the tangles in the fibers are removed and they are straightened by carding. To ensure uniform feeding to carding machine, the present invention adopts the chute feeding method. The fiber mat fed to the carding machine should be of a high degree of uniformity to ensure consistent opening and carding .This uniformity is achieved using the chute feed system, which aims at feeding a fiber sheet of a uniform packing density and uniform linear density (weight per unit length) to the carding machine. The journey of fibers through the carding process being with feeding a uniform fiber mat prepared by the chute feed system and supplied to the carding machine using feed roller. This weight approximately corresponds to a number of fibers in the mat cross section in the range from 2 to 6 millions of fibers depending on fiber fineness.
Followed by the step of carding, the cotton is subject to breaker drawing and unilap to produce slivers that are combined. As a result a relatively narrow lap of compactly placed staple fibers are drawn out which are of smaller diameter that do not fall apart.
Subsequently, the slivers are strengthened in the comber to produce a long-staple yarn which is stronger and smoother as required by the invention.

The yarn is further subject to finishing in a finisher and drawing. With the help of auto levelers a uniform drawing is achieved along with the elimination of irregularities in the yarn. Finally the cotton undergoes the steps of simplex, spinning, autoconer, doubler J wining, Two For One twister (TFO), ring doubling, gassing, winding, inspection.
i J
! The process of twisting is an indispensable means of improving certain yarn properties and satisfying textile requirements that cannot be fulfilled by the single yarns. The methods of twisting two or more single yarns are called doubling or folding or ply twisting. Such yarns are designated as doubled yarn, folded yarn or plied yarn and the machines intended for the purpose are called doublers, ply-twisters or two-for-one (TFO) twisters.
Traditionally, ring doublers were used for ply twisting spun yarns and uptwisters were used for twisting filament yarns. Now-a-days, TFO twisters are gaining world-wide acceptance in both spun yarn and filament yarn sectors mainly because of their inherent advantages like (1) production of long length of knot free yarns which facilitates better performance in the subsequent processes and (2) higher productivity.
Twist is needed in yarn to hold the fibres together, and is added in both the spinning and plying processes. The amount of twist varies on the fibre, thickness of yarn, preparation of fibre, manner of spinning, and the desired result.
The amount of twist in a yarn helps to define the style of yarn- a yarn with a lot of air such as a woolen yarn will have much less twist than a yarn with little air, like a worsted yarn. It also affects the stretchiness of the yarn, strength, the halo of the yarn, and many other attributes. Filling or weft yarns usually have fewer twists per inch because strength is not as important as with warp yarns, and highly twisted yarns are, in general, stronger. Warp yarns have to be stronger so that they can withstand the tension of the loom.

The number of twists per inch can, in plied yarns, be determined by counting the number of bumps in one inch, and divide by the number of singles (the strands plied together to make the yarn.
The twist directions of the yarn contribute to the fabric manufactured. The twist direction
%
i in warp and weft yarn and the weave direction influence the sheet produced. In view of > this the twist direction in warp and weft yarn and the weave direction are carefully chosen
5 so that the right combination of yarn twists and weave direction contribute to improved
f
« luster and tenderness to the fabric.
I
Thread count is often used as a measure of fabric quality, so that "standard" cotton thread counts are around 150 while good-quality sheets start at 180 and a count of 200 or higher is considered percale.
According to the invention to achieve this, a fiber having threads per inch (TPI) of 34 to 39 is applied for warp and 38 to 41 in the weft is applied to ensure a soft feel in the final product. It is further preferable to use a single ply or two ply yarns in the warp and a single ply yarn in the weft to achieve the best weave geometry and structure which leads to better handing and elegant feel.
Increased thread count refers to packing of more number of threads per square inch. In order to achieve this, the thread needs to be very fine in nature and should have an excellent strength to withstand the stress and stains of weaving and other subsequent process. This is achieved by using extremely high quality cotton fibres which possess high fiber length, fineness and strength.
Current manufacturing as per the prior art are single ply fabrics which limits thread count to about 500-600 threads per square inch. After that, all fabrics are multi ply. Fabrics over
1000 TC are most likely triple ply or more. These super high thread count fabrics are not
J.
^ necessarily of lower quality, they may be of feel great. This is only because multi ply
«<•; sheets are usually made of shorter fiber cotton so that they will pill more easily but they
*-' are less durable. Further, such fabrics are thicker and heavier. However, in view of the

nature of the raw material that we use and the process parameters involved in producing the fabric the sheeting fabric produced according to the present invention is stronger, has a high tear resistance and tensile resistance.
An optimum TPI of 34.47 is applied for warp and 38.68 in the weft to ensure a soft feel in the finally produced 600TC sheeting fabric.
The specifications for 800 TC fabrics is as follows:
Construction Count GSM
EPIX PPI = 196 X 204(11) 2/120s x 2/140s 150
An optimum TPI of 38.67 is applied for warp and 41 in the weft to ensure a soft feel in the finally produced 1000 TC sheeting fabric.
Two ply yarns have been used both as warp & weft and as both to achieve the best weave geometry and structure which leads to better handle and elegant feel.
More preferably, according to the invention it is preferred to use a double yarn as double yarn generally registers higher shrinkage when compared to single yarn. As understood by an artisan higher shrinkage will always lead to higher crimp and fabric bulkiness which in turn naturally contribute to better drape of the fabric.
In the prior art it is known that a multi ply thread is usually weaker than a single ply, not only because the twisting makes them weaker but also because they are shorter and pill easily and hence are less durable even though they are thicker. But according to the present invention since the cotton fibers are long they contributing to stronger and smoother sheeting fabric, even if they are a multi-ply fabric.
The second step of manufacture is weaving. The weaving process involves warping, sizing, before the actual weaving.

Warping is done to avoid excessive stretching of the yarn in order to maintain uniformity in the bulkiness of the yarn during the entire lot of production, the Warping according to the present invention is done in sectional warping machine and beam to beam sizing. This helps to eliminate any stress and strain imposed on the yarn during regular sizing process.
Sizing is carried out with natural ingredients such as starch of maize, corn, rice, potato and Vegetable oils, which are easily washable are used. This helps to retain the soft feel and luster of cotton.
Subsequent to sizing the yarns are subject to drawing-in & denting. Drawing-in & Denting is a process of drawing every warp yarns through the drop wire, heald eyes and reed dent of weaving machine.
This is followed by weaving, which is done in Airjet looms. The fully Automatic air jet looms are used at optimum speed to ensure soft handling of yarn and enhance fabric quality. The pick insertion is soft and less strained. This ensures that there is a non-elongation of the weft yarns during weaving which results in softness of the fabric produced.
According to the prior art, a weight of 130-160 GSM will suit for sheeting fabrics. But, the present invention maintains a weight of 140 GSM to 190 GSM inclusive for the sheeting fabric. Preferably, for a 600 TC fabric a weight of 140 GSM is maintained. For 800TC fabric a weight of 150 GSM is maintained. For a 1000TC fabric weight of 186 GSM is maintained.
The last step in the manufacture of sheeting fabric is the finishing step.
In an embodiment, the weft yarn can be mechanical plied or chemically laminated to form bonded threads. Mechanical plying is a process used to create a strong, balanced yarn. It is done by taking two or more strands of yarn that each has a twist to them and putting them together. The strands are twisted together, in the direction opposite that in which they were spun. When just the right amount of twist is added, this creates a balanced yarn,

which is a yarn with no tendency to twist upon itself. A two-ply is thus a yarn plied from two strands; a six-ply is one from six strands, and so on.
Chemical lamination occurs through the use of an adhesive. The adhesive can be applied : to the web as a printed pattern or as a sprinkling of powder. The properties of the \ adhesive bonded non-woven depend to a quite large extent on the properties of the
adhesive polymer used. Commonly used adhesives are polyvinyl acetate,
poly aery lonitrile, PVC.
In an embodiment, the two threads are chemically bonded together with the help of an adhesive. This ensures uniform spacing the threads in weft way which helps to retain a uniform structure of warp interlacement and hence an improved appearance and luster, and eliminating the chances of two threads overlapping each other once woven in to the fabric.
Suitable adhesives which can be used for the purposes of the present invention can be selected from polyvinyl acetate, polyacrylonitrile and other adhesives which are either Vinyl based or Acrylic based.
Further using finer counts in warp helps in packing more threads in warp way compared to the conventional fabric. Increased warp density will reduce the space between the threads in warp way and the diagonal lines of weave structure will become more prominent. This will enhance the lustrous appearance of the fabric.
In an embodiment, for producing a 600 TC fabric two threads of 120 Ne are bonded together with the help of an adhesive and used as warp. Similarly two threads of 140 Ne is bonded together and used as weft. Usage of bonded threads and absence of twists results in extremely good softness.
In an embodiment, for producing an 800 TC fabric 2/120 Ne gassed 2 ply yarn in the warp are used. Since the count of single yarn is 120 Ne, it is plied with sufficient twists to make it rigid and stronger enough for the weaving process. Twists in the yarn will impose

a crispy rough feel to the fabric, which may not be an appealing factor for a high end sheeting fabric.
In an embodiment, for producing 1000 TC fabrics, two threads of 140 Ne are bonded together with the help of an adhesive and used as warp. Similarly four threads of 170 Ne is bonded together and used as weft. Usage of bonded threads and absence of twists results in extremely good softness.
A specially designed Italian machine helps to bond the longitudinal surfaces of 2 threads continuously with the help of a high sensitive adhesive. The adhesive applied will be completely dissolved during the weft processing & finishing. The yarn is unwound from the supply package through the yarn guides and tension disc. Later than the yarns are prepared as a sheet form for laminate with the special Acrylic based adhesive. The laminated yarn sheet goes through the squeeze roller and it gets dried in drying chambers. Finally the yarns are wound on the spindles.
The fabric is subjected to additional processes called Aero finish in the final processing. There is a special machine for this purpose called Biancalani which uses air at a very high pressure. The fabric is passed in a relaxed stage through chambers of severe and continuous air turbulences.
Fabric moves as very high speed, suspended and transported by the air flow, inside a special duct or channel. The air is taken from the surrounding area in adjustable amounts by means of a special high efficient centrifugal fan system and is injected into the channel in alternate directions at extremely high speed. This improves the hand and look of the fabric with considerable effect on its quality which gives soft touch, body and drape on fabrics.
The amount of water used here is comparatively less and no chemicals are used for this process. Hence this process is eco friendly as well.

Loose fibres protruding on the surface of textile goods are singed to remove them. When done to fabrics containing cotton, this results in increased wettability, better dyeing characteristics, improved reflection, no "frosty" appearance, a smoother surface, better clarity in printing, improved visibility of the fabric structure, less pilling and decreased contamination through removal of fluff and lint.
The process is usually to pass one or both sides of a fabric over a gas flame to burn off the protruding fibres. Other methods include infra-red or heat for thermoplastic fibers. Singeing of yarns is called "gassing". It is usually the first step after weaving or knitting, though the fabric may be brushed first to raise the surface fibres.
Cellulose fibres such as cotton are easily singed because the protruding fibers burn to a light ash which is easily removed. Thermoplastic fibres are harder to singe because they melt and form hard residues on the fabric surface.
The chemicals used for processing are eco friendly and would not endure any harmful effect to the applicants. The fabric is singed twice to burn off any minute airiness from both sides of the fabric. By subjecting the fabric for mercerizing twice, the uniformity, luster and softness of cotton is further improved. The fabric is sanforized to stabilize the shrinking character within the norms.
The fabric is woven in 5 end satin warp way satin at 2 move number technique is used for an effective bedding of warp and weft yarns to ensure a thin and compact fabric.
The fabric is constructed having from 90 to 120 ends per inch, in particular from 95 to 115 ends per inch of the cotton warp yarn, and from 65 to 95 picks per inch, in particular from 70 to 90 picks per inch of the multifilament polyester yarn. The total thread count may range from 170 to 215, in particular, from 170 to 200. The warp-to-fill ratio may range from 1.1:1 to 1.5:1, in particular from 1.2:1 to 1.4:1.
The number of ends per inch varies on the pattern to be woven and the thickness of the thread. Plain weaves generally use half the number of wraps per inch for the number of

ends per inch, whereas denser weaves like a twill weave will use a higher ratio like two thirds of the number of wraps per inch. Finer threads require more threads per inch than thick ones, and thus result in a higher number of ends per inch.
The number of ends per inch in a piece of woven cloth varies depending on what stage the cloth is at. Before the cloth is woven the warp has a certain number of ends per inch, which is directly related to what size reed is being used.
The fabrics according to the present invention possess certain uniqueness in their appearance and hand feel, which is achieved by appropriate selection of raw material, manufacturing methodology and process parameters.
In various forms, the fabric of the invention may be used as a bed sheet, a component of a comforter, a component of a mattress pad, a component of a decorative pillow, a component of a feather bed, a component of a window treatment, a component of a blanket or throw blanket, or one from the group consisting of a sheet set, a bed skirt, a sham, drapes, valances, tie backs, curtains, bed pillows, throw blankets, bed blankets, and window treatments, or as otherwise used in the manufacturing and offerings of the home textiles industry.
The following examples are provided to better illustrate the claimed invention and are not to be interpreted in any way as limiting the scope of the invention. All specific materials, and methods described below, fall within the scope of the invention. These specific compositions, materials, and methods are not intended to limit the invention, but merely to illustrate specific embodiments falling within the scope of the invention. One skilled in the art may develop equivalent materials, and methods without the exercise of inventive capacity and without departing from the scope of the invention. It is the intention of the inventors that such variations are included within the scope of the invention.

EXAMPLES
EXAMPLE 1
A sheeting fabric of 600 TC, 800 TC and 1000TC was constructed according to the present invention with the following process sequence:
Selection of raw material — Spinning and Winding—Lamination—Warping—Sizing-s —Drawing-in & Denting—-Weaving
^ Given below is the list of parameters used in the present example to manufacture the \ sheeting fabrics indicated above.
List of Parameters from fiber to fabric used for 600,800, and 1000 Thread count
Selection of raw material:
The raw material is selected from cotton which is longer and stronger. The finer yarns according to the present invention have several special features as mentioned below.
• Less hairy
• Excellent uniformity of the texture

• Good strength characteristics
• Extremely lustrous
• Rich to handle
Further, the selected cotton varieties have the maximum moisture regain characteristics. Besides the properties indicated in the table above, the fibers have the following qualities:
Spinning and Winding:
The fibers are spun and wound as per the process of the present invention.
Lamination:
The wound fibers (web) are subjected to a Chemical lamination i.e., by applying the adhesive on the web as a printed pattern or by sprinkling of the powder. The adhesives are selected from polyvinyl acetate, polyacrylonitrile and other adhesives which are either Vinyl based or Acrylic based.
Warping:
The laminated web is subject to warping in a sectional warping machine to prepare warp beam.
Sizing:
The web is subjected to sizing with natural ingredients such as starch of maize, corn, rice, potato (Soloact, Polyplast, alphenol etc..) and Vegetable oils, which are easily washable.

Drawing-in & Denting:
Drawing-in & Denting is a process of drawing every warp yarns through the drop wire, heald eyes and reed dent of weaving machine.
Weaving and finishing:
The weft yarns are woven in Air-jet looms and the final sheeting fabric thus produced is subject to the finishing step.
The sheeting fabrics thus produced had the following parameters:
The sheeting fabrics were tested and found to have the following performance
Characteristics:
600TC 800TC 1000TC
Tensile strength (warp): 57 lbs 64 lbs 65 lbs
Tensile strength (weft): 40 lbs 50 lbs 52 lbs
Tear strength (warp): 12.95 lbs 14 lbs 14.51bs
Tear strength (weft): 7.0 lbs 14.08 lbs 16 lbs
The 600TC, 800TC and lOOOTc sheeting fabric are produced using the following parameters and are tested at every stage of manufacture to ensure the product standards as prescribed.
The parameters measured on 600 TC sheeting fabric is:

The parameters measured on 800 TC sheeting fabric are:
The parameters measured on 1000 TC sheeting fabric are:
Example 2: Comparison of physical properties of the fabric obtained by the process of the present invention with the fabric available in the market.

We Claim:
1. A 100 % cotton fabric sheeting with improved feel and improved tensile and tearing strength said sheeting being formed using chemically laminated threads, wherein the weft and warp yarns are comprised of two or more threads of yarn bonded together with the help of an adhesive, wherein the chemical lamination of the threads is by applying adhesives.
2. The 100 % cotton fabric sheeting as claimed in claim 1, wherein the yarn used for its construction is a Ne 20 to Ne 400 yarn.
3. The 100 % cotton fabric sheeting as claimed in claim 1, wherein the adhesive used for bonding the Ne threads is selected from polyvinyl acetate, polyacrylonitrile, and PVC.
4. The 100 % cotton fabric sheeting as claimed in claim 1, wherein the fabric has a tensile strength in warp direction of atleast 50 lbs and weft direction of atleast 40 lbs.
5. The 100 % cotton fabric sheeting as claimed in claim 1, wherein the fabric has a tearing strength in warp direction of atleast 10 lbs and weft direction of atleast 15 lbs.
6. A process for production of the sheeting fabrics as claimed in claim 1, comprising the steps of:
a. Selection of raw material,
b. spinning;
c. weaving; and
d. finishing of the product.
7. The process as claimed in claim 6, wherein the fiber quality index for the warp yarn ranges between 116 to 125, and for the weft yarn ranges between 89 to 144.
8. The process as claimed in claim 6, wherein the fiber strength ranges between 28g/tex to 34 g/tex for warp yarn, and ranges between 27 g/tex to 34 g/tex for weft.

9. The process as claimed in claim 6, wherein the yarn used has a TPI of 34 to 41.
10. The process as claimed in claim 6, wherein a single ply or multi ply yarn is used in warp for spinning.
11. The process as claimed in claim 6, wherein warping is carried out in a sectional warping
3> machine during weaving.
^.
_•»
U
"* 12. The process as claimed in claim 6, wherein the weaving process further consists of:
j a) warping in a sectional warping machine,
b) sizing using natural ingredients, and
c) Weaving in airjet looms.

13. The process as claimed in claim 6, wherein a weight of 140 GSM to about 190 GSM is used during weaving.
14. The process as claimed in claim 1, wherein the adhesive used for lamination is selected from polyvinyl acetate, polyacrylonitrile and other adhesives which are either Vinyl based or Acrylic based
15. A process for manufacturing 100% cotton sheeting fabric having a tensile strength of 600 comprising the steps of:
a) Selecting a fabric having a fiber quality index of 116 for warp yarn, and 89 for weft yarn, and a fiber strength of 28.6 g/tex for warp yarn, and 27 g/tex for weft yarn.
b) spinning the yarn at a TPI of 34.47 for warp and 38.68 for weft,
c) weaving using a sectional warping machine using a weight of 140 GSM,
d) chemically laminating the yarn using an adhesive, and
e) Aero finishing the final product.

16. A process for manufacturing 100% cotton sheeting fabric having a tensile strength of 800
comprising the steps of:
a) Selecting a fabric having a fiber quality index of 116 for warp yarn, and 125.5 for weft yarn, and a fiber strength of 29.9 g/tex for warp yarn, and 33.5 g/tex for weft yarn.
b) spinning the yarn at a TPI of 34.47 for warp and 38.68 for weft,
c) weaving using a sectional warping machine using a weight of 150 GSM,
* d) chemically laminating the yarn using an adhesive, and
j
y e) aero finishing the final product.
J >
17. A process for manufacturing 100% cotton sheeting fabric having a tensile strength of
1000 comprising the steps of:
a) Selecting a fabric having a fiber quality index of 125 for warp yarn, and 143.9 for weft yarn, and a fiber strength of 33.5 g/tex for warp yarn, and 31.9 g/tex for weft yarn.
b) spinning the yarn at a TPI of 38.67 for warp and 41 for weft,
c) weaving using a sectional warping machine using a weight of 186 GSM, and
d) chemically laminating the yarn using an adhesive, and
e) aero finishing the final product.