Patent Application
20170079444
Not applicable.
Not applicable.
A mattress topper is a cushioned item of removable bedding that typically sits on the top surface of a mattress. Mattress toppers may be used to promote increased comfort to a user while sleeping and may also protect a mattress hygienically and physically, such as from wear and tear imposed by use. Typically, a removable outer cover (and only the removable outer cover, for example not the actual cushioning element(s)) of a conventional mattress topper may be washed. regularly to maintain clean bedding. Applicant has developed a washable mattress topper, which may be repeatedly washed and dried as a whole (e.g. in its entirety, for example more than just the cover, including for example the cushioning element) without significantly damaging the cushioning element of the topper. These and other improvements are discussed below in more detail.
For a more complete understanding of the present disclosure, reference is now made to the following brief description, taken in connection with the accompanying drawings and detailed description, wherein like reference numerals represent like parts.
It should be understood at the outset that although illustrative implementations of one or more embodiments are illustrated below, the disclosed systems and methods may be implemented using any number of techniques, whether currently known or not yet in existence. The disclosure should in no way be limited to the illustrative implementations, drawings, and techniques illustrated below, but may be modified within the scope of the appended claims along with their full scope of equivalents.
The following brief definition of terms shall apply throughout the application:
The term “comprising” means including but not limited to, and should be interpreted in the manner it is typically used in the patent context;
Directions, such as up (e.g. upward) and/or down (e.g. downward), typically are intended to be based on the mattress (or sleep system or foundation) in its normal sleeping position as understood by persons of skill; for example, the upper surface of the mattress might face towards the ceiling and/or serve as the sleep surface upon which the user might lie, while the bottom surface of the mattress might face towards the floor or ground and/or be placed atop a foundation element;
The phrases “in one embodiment,” “according to one embodiment,” and the like generally mean that the particular feature, structure, or characteristic following the phrase may be included in at least one embodiment of the present invention, and may be included in more than one embodiment of the present invention (importantly, such phrases do not necessarily refer to the same embodiment);
If the specification describes something as “exemplary” or an “example,” it should be understood that refers to a non-exclusive example;
The terms “about” or approximately” or the like, when used with a number, may mean that specific number, or alternatively, a range in proximity to the specific number, as understood by persons of skill in the art field (for example, +/−10%); and
If the specification states a component or feature “may,” “can,” “could,” “should,” “would,” “preferably,” “possibly,” “typically,” “optionally,” “for example,” “often,” or “might” (or other such language) be included or have a characteristic, that particular component or feature is not required to be included or to have the characteristic. Such component or feature may be optionally included in some embodiments, or it may be excluded.
Embodiments relate generally to mattress toppers (or other cushioned support devices) which may be made washable as a whole (for example, allowing multiple washing and drying cycles, for example in typical washer and drier units, without significant degradation to the cushioning element(s) of the topper). Disclosed embodiments provide an improvement/enhancement to an earlier washable mattress topper developed by the Applicant, namely the washable topper set forth in U.S. Pat. No. 8,966,688 (hereby fully incorporated by reference to the extent it does not directly contradict the immediate disclosure herein), which used compartmentalization of the cushion element (which typically comprised an open cell foam material) of the topper (or device). Typically, such compartmentalization was accomplished by quilting techniques, with stitching passing through the ticking forming the upper and lower surface of the outer cover of the topper, as well as the open cell foam cushion element. While embodiments of the present improvement/enhancement often may include compartmentalization similar to that described in U.S. Pat. No. 8,966,688, they also typically comprise different cushioning/support materials/elements (instead of (or in some embodiments, in addition to) the open cell foam described in the earlier patent, for example). Consequently, the disclosed embodiments herein may provide even further improvement in washability and/or may be lighter in weight and/or thickness (which may improve machine washability) while still providing effective cushioning/support (for example comparable to the earlier washable topper discussed above). These enhanced topper embodiments will be described in more detail below.
While the embodiments described below may discuss mattress toppers, it should be understood that use of the term “mattress topper” or “topper” herein is merely exemplary and may not be limiting, and that embodiments may also relate to other cushioned support devices (such as pillows, mattresses (or elements within a mattress), for example). Furthermore, while the enhanced washable mattress topper examples herein may generally be discussed in the sleeping context or for use on the top surface of a mattress, enhanced washable cushioned support devices (with similar features) may have other uses (for example, seating cushions or lumbar support cushions), all of which are within the scope of this disclosure.
Mattress toppers generally are designed for the purpose of increased comfort while sleeping and to protect mattresses hygienically and/or from wear and tear. It is typically not common practice to wash an entire conventional topper because it may cause deterioration (and typically significant deterioration of the cushioning element of the topper. However, a washable mattress topper (for example, allowing the entire topper to be washed, including the cushioning element(s) as a whole and/or all together at one time) may be desired to allow for more hygienically clean bedding. So, it may be desirable that a mattress topper be machine or hand washable for hygienic reasons, including the elimination of dirt, allergens and other irritants (e.g. dust mites, bed bugs, mold and dead skin).
The cushioning element(s) (e.g. the cushioning/support material located between the cover/ticking) of disclosed embodiments may comprise a fiber-foam layer and/or a spacer fabric layer (and typically would comprise both fiber-foam and spacer fabric, for example, instead of typical open and/or closed cell foam). For example, spacer fabric might be laminated to at least one surface of the fiber-foam layer, to form a cushioning element for the enhanced washable mattress topper (and in some embodiments, spacer fabric might be laminated to both the upper and lower surface of the fiber-foam layer). So for example, an exemplary enhanced washable mattress topper might comprise a fiber-foam layer, a spacer fabric layer, and a ticking or cover which encompasses both the fiber-foam layer and the spacer fabric layer to form the exterior of the topper (for example, with an upper/sleep support surface and a bottom surface configured to lay atop the mattress).
Some disclosed embodiments may comprise the attachment of a fabric cover (e.g. ticking) to the cushion element of a mattress topper in a manner that creates a plurality of compartments within the cushion element, wherein the fabric cover permanently encloses the cushion element. In this disclosure, “permanently enclose” means that it may be possible to remove the fabric cover by laboriously cutting or otherwise removing the attachment between the cover and the cushion element (which may he stitches, for example), but this removal may effectively destroy or ruin the mattress topper. At the least, it would be very inconvenient to remove the fabric cover, and removal would defeat at least one of the benefits of the invention, including the ability to wash the topper without having to remove and later reinsert the cushion element. In the language of this disclosure, “permanently” means that the fabric cover remains in enclosure of the cushion element for the duration of the functional life of the disclosed mattress toppers. So for example, the compartments might be formed by quilting/stitching the cover to the one or more cushioning elements, for example with stitching passing through the upper cover/ticking layer/surface, the one or more cushioning elements, and the bottom/lower cover/ticking layer/surface. While the creation of a plurality of compartments within the cushion element (e.g. the fiber-foam layer and the spacer fabric layer) by attachment of the cover is typically used in such disclosed embodiments (to improve washability), some embodiments may not require such compartmentalization (for example, relying on the use/selection of fiber-foam and spacer fabric for the cushion element to provide the desired washability).
So, disclosed embodiments typically would comprise a spacer fabric layer and a fiber-foam layer (which jointly form the cushioning element of the topper), along with a cover/ticking which encompasses the cushioning element (i.e. the spacer fabric and fiber-foam). Typically, the spacer fabric would be laminated to the fiber-foam layer, to jointly form the cushioning element of the topper (although in other embodiments, the spacer fabric and the fiber foam layer might only be joined by the stitching of the quilting pattern for attachment of the cover). And typically, the cover/ticking would be quilted/stitched onto the cushioning element (e.g. spacer fabric and fiber-foam layer), permanently joining the cover to the cushioning layer. In most disclosed embodiments, the quilting approach would have stitching (which passes through both the upper and lower layers/surfaces of the cover and the fiber-foam layer and the spacer fabric) which divides or segments the cushioning element into a plurality of compartments.
Some embodiments might comprise two spacer fabric layers, with an upper spacer fabric laminated atop (and in direct contact with) the fiber-foam layer, and a lower spacer fabric layer laminated beneath (and in direct contact with) the fiber-foam layer (such that the cushioning element might be formed of the fiber-foam layer and two spacer fabric layers). Most often, if there are two spacer fabric layers, these spacer fabric layers would be identical (in material, thickness, etc.), although in other embodiments the upper spacer fabric layer and the lower spacer fabric layer could be different (for example, formed of different material, have different dimensions, and/or have different properties). Some embodiments might also optionally comprise a non-slip (for example PVC) layer (which could be the lower cover surface/layer in some embodiments or could be a separate layer located beneath the cushioning element and between the cushioning element and the lower cover layer in other embodiments).
Typically, the fiber-foam layer would comprise fibers distributed approximately evenly throughout the foam material, and typically, the ratio of fibers to foam would be approximately a level providing effective support/comfort characteristics. In some embodiments, the fiber-foam material might comprise polyurethane (for example, open cell in some embodiments) foam and polyurethane fibers.
Typically, the spacer fabric layer(s) would be formed of spacer fabric, for example a 3D warp knit fabric product, which might be knitted in a lofted manner (for example, with a middle layer of monofilament yarn sandwiched between and connecting two outer surface layers of fabric). Typically, the outer layers of fabric forming the spacer fabric would be an open mesh fabric material, such that the spacer fabric might comprise an upper surface of mesh fabric, a lower surface of mesh fabric, and a 3D spacer microfilament yarn layer knit between and connecting the upper and lower mesh fabric surfaces. Typically, the ratio of spacer fabric layer thickness to fiber-foam layer thickness in the cushion element might be approximately 1:1 or 1:1.5 (for example, ith the spacer fabric layer perhaps having an uncompressed thickness of about 1-1.5 cm (for example approximately 1 cm) while the fiber-foam layer might have a thickness of about 1-1.5 cm, 1-2 cm, or 1.5-2 cm (for example, approximately 1.5 cm)). And typically, the airflow rate of the spacer fabric layer might be sufficient to allow for effective drying.
Typically, the ticking/cover would be fabric and typically would be permanently attached to the cushion element, for example by stitching (which might form a quilting pattern, for example, forming a plurality of compartments segmenting the cushion element). So for example, the ticking/cover might comprise an upper surface layer and a lower surface layer, with the cushion element located between (and typically in contact with) the upper surface layer and the lower surface layer of the cover, and stitching (for example, forming a quilting pattern resulting in a plurality of compartments) might pass through the upper surface layer of the cover, through the cushion element (for example through both the fiber-foam layer and the one or more spacer fabric layers), and through the lower surface layer of the cover (e.g. joining both the upper and lower surface of the cover to the cushion element, as well as further joining (and often compressing and locking in (e.g. securely fixing) the compression) the spacer fabric to the fiber-foam). So for example, the thickness of the cushion element at the stitching might typically be the thickness at which the cushion element is compressed (for example, to about its maximum compression).
In some embodiments, more than one type of stitching might be used to form the quilting (e.g. permanently attach the cover to the cushion element). So for example, a combination of tack-and-jump stitching and channel stitching might be used, for example with the channel stitching connecting points tacked by the tack-and-jump stitching. Furthermore, the channel stitching might comprise 4-8 stitches per inch (for example, perhaps 6 stitches per inch). The stitching might form a plurality of compartments dividing the cushion element, such that all of the plurality of compartments might have approximately the same thickness of cushioning (resulting from being formed by division of the same unified cushion element by stitching). And often, several (and sometimes all) of the plurality of compartments might be equally shaped and sized (e.g. identical). In sonic embodiments, several of the compartments might be rectangular, triangular, or helical in shape. In some embodiments, there may be a border compartment about the perimeter of the topper, with a plurality of central compartments located within the border compartment. In such instances, the central compartments typically would be equally sized and/or shaped.
The illustrative examples shown in the figures and described below may provide more detailed examples of the disclosed enhanced washable mattress topper embodiments.
In an embodiment, the fabric cover 104 may be attached to the cushion element 102 by stitching with thread 110 and 112 through both the fabric cover 104 (for example, both the top surface 1.20 and the bottom surface 130 of the cover) and the cushion element 102. In an embodiment, stitching continuous lines with thread may achieve compartmentalization of the mattress topper 100. “Continuous” may refer to stitching without breaking/cutting the thread at any point in a particular line/distance. Although, in an embodiment, the thread may be visible on one side of the fabric cover 108 in a dashed fashion (such that the stitching alternates between two surfaces 120 and 130 of the fabric cover 104), it may be considered a continuous stitch if the thread used to make the stitch is not broken and/or cut along a specific line. In an embodiment, a stitching pattern on a topper 100 (such as may be formed by stitching 110 and 112) may be formed by one or more continuous lines of stitching. For example, in
While one embodiment of compartmentalization of the mattress topper may be achieved by stitching continuous lines with thread (for example, forming a quilting pattern), other methods are equally contemplated, such as stitching without continuous lines, fusing, use of adhesive, use of rivets, use of buttons or some combination thereof. Additionally, an embodiment of the mattress topper shown in
In an embodiment, the stitching 110 and 112, operable to attach the cushion element and fabric cover, may be in a pattern such that the number of stitches per inch may be between about 4 and about 8, and in some embodiments, may comprise between approximately 5 to 7 stitches per inch. In a typical embodiment, the stitching pattern 110 and 112 may comprise approximately 6 stitches per inch. In an embodiment, the thread used for the stitching may comprise Nylon and may have a thread weight of at least approximately Tex 6 (wherein Tex is the mass in grams of 1000 meters of thread). In other embodiments, the thread may comprise other materials such as cotton, polyester, a cotton-polyester blend, rayon, silk, or wool, which may be chosen based on the desired qualities of the thread such as strength, thickness, appearance, stability during washing and/or drying, and/or cost. In an embodiment, the stitching 110 and 112 may be completed using one or more quilting/stitching methods, which may include channel stitching and/or tack-and-jump. In an embodiment, the fabric cover 104 and cushion element 102 may first be tacked together (i.e. tacked with thread from one surface of the fabric cover to the other surface through the cushion element) in a plurality of points on the topper 100 (which may be located within the stitching pattern 110 and 112) using a tack-and-jump method. Then, channel stitching may be used to form the final pattern of stitching 110 and 112 on the topper 100 that may ultimately create the plurality of compartments 106 and 108 in the topper 100. In an embodiment, the channel stitching may connect the plurality of points that may be tacked by the tack-and-jump method. The embodiment of attaching the fabric cover 104 and cushion element 102 combining the use of tack-and-jump and channel stitching may allow for increased stability of the cushion element 102 in the stitching pattern. In an embodiment, the tack-and-jump followed by channel stitching may firmly fix the cushion element 102 within the pattern of compartmentalization, such that during washing and/or drying, the cushion element 102 and/or the fabric cover 104 may not develop puckers or deformities at or around the stitching 110 and 112.
The size and/or shape of the compartments may affect the comfort of the topper 100 for a user as well as manufacturing costs associated with the topper 100. In the embodiment shown in
In an embodiment, a topper 100 without a border compartment 108 may develop irregularity in deformation or decomposition at the edges of the topper caused by washing and/or drying of the topper. Typically, a topper without a border compartment may have a lifespan of about 25 to 30 washes, whereas a topper with a border compartment may have a lifespan of at least 40 washes or more (which may be the equivalent of 20 years with 2 washings a year). The border compartment 108 may create strength for the cushion element 102, at the outer edges, especially at the corners, and serve to reinforce them during washing and/or drying. Additionally, the border compartment 108 may reinforce the stability of the topper 100 during regular use of the topper 100, such as when a user moves onto or off of the topper 100 or to a different position on the topper 100.
While many embodiments may comprise both a border compartment and a plurality of central compartments, other embodiments may comprise either just a border compartment alone (e.g. surrounding just one large central compartment) or just a plurality of central compartments alone (e.g. a plurality of compartments spanning the enter portion of the topper without an enclosing border compartment located about the edges of the topper upper surface). Persons of skill will understand the various combinations of compartments, several of which will be illustrated in more detail below with respect to specific figures. It may even be possible in some embodiments to have a washable topper without such compartments (for example, due to the nature of the cushion element with fiber-foam and spacer fabric), although typically even disclosed toppers with fiber-foam and spacer fabric would comprise at least one compartment (formed by quilting, for example), as discussed above.
In an embodiment, the cushion element 102 may comprise an uncompressed thickness up to approximately 2.5 inches. An embodiment of the cushion element 102 may have an uncompressed thickness of at least 1 inch, ranging from 1-1.5 inches, and/or may typically be about 1.5 inches thick. Different factors that may be considered to determine an optimal thickness of a topper 100 may include user comfort, ability to be washed and/or dried, and/or ability to be sewn through with stitching to create compartments. In an embodiment, the thickness of the cushion element 102 may be such that it allows for a user to handle (i.e. move, wash, and/or dry) the topper 100 with relative ease while still retaining comfort properties of the topper 100. A desired thickness may also depend on the density of the topper 100, wherein a typical embodiment of the cushion element 102 may comprise a density of about 3 lb. per board foot (wherein 1 lb. per board foot may be the equivalent of 12 lb. per cubic foot), or in some embodiment a density of less than 3 lb. per board foot. Because a typical mattress topper 100 may spend the majority of its lifespan on the top surface of a mattress, the topper 100 may not be made to be easily rolled or folded for storage; therefore the thickness of the topper may not need to be designed with folding or rolling characteristics.
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Formation of disclosed topper embodiments might comprise one or more of the following steps: selecting cover material (for example, based on airflow rate, ability to resist shrinking and/or stretching during washing and/or drying, density/weight, etc.) and forming a cover (which for example, might initially be formed as an envelope operable to encompass a cushion element for a topper and open on one side (to allow for insertion of the cushion element), for example sized to one of the standard mattress sizes (for example, twin, full, queen, king, etc.)); selecting cushion material(s) (for example, based on airflow rate, ability to resist shrinking and/or stretching during washing and/or drying, density/weight, etc.) and forming a cushion (for example with spacer fabric and fiber-foam, which might be placed in contact and/or laminated to each other) sized to one of the standard mattress sizes and sized to fit in the cover; inserting the cushion element into the cover (or otherwise enveloping the cushion element with the cover, so that the cover encompasses the cushion element); closing (for example, with stitching) the cover (so that the cover completely encompasses the cushion element); and stitching through the cover (e.g. both the upper and lower surfaces of the cover) and the cushion element to form one or more compartments (e.g. permanently attaching the cover to the cushion element while also compartmentalizing the cushion). Typically, the cushion element might be compressed during stitching, so that the stitching holds the cushion element at those stitch points in compression, while also permanently affixing the cover to the cushion element (as well as the spacer fabric to the fiber-foam layer) at the stitching points. Typically, the stitching might comprise tack-and-jump stitching and/or channel stitching (and typically a combination, as previously discussed). And typically, one or more continuous lines of stitching would be used to form the compartments and/or permanently affix/attach the cover to the cushion element. In some embodiments, forming compartments might include forming a border compartment around the exterior of the topper (for example, with continuous stitching inset 1-3 inches from the edges) and/or forming one or more central compartments within the border compartment. In other embodiments, forming compartments might comprise forming a plurality of compartments without a border compartment (for example, with rectangular compartments extending across the width or length of the topper). The stitching process could form any of the quilting patterns discussed above, by way of non-limiting example.
While various embodiments in accordance with the principles disclosed herein have been shown and described above, modifications thereof may be made by one skilled in the art without departing from the spirit and the teachings of the disclosure. The embodiments described herein are representative only and are not intended to be limiting. Many variations, combinations, and modifications are possible and are within the scope of the disclosure. Alternative embodiments that result from combining, integrating, and/or omitting features of the embodiment(s) are also within the scope of the disclosure. Accordingly, the scope of protection is not limited by the description set out above, but is defined by the claims which follow, that scope including all equivalents of the subject matter of the claims. Each and every claim is incorporated as further disclosure into the specification and the claims are embodiment(s) of the present invention(s). Furthermore, any advantages and features described above may relate to specific embodiments, but shall not limit the application of such issued claims to processes and structures accomplishing any or all of the above advantages or having any or all of the above features.
Additionally, the section headings used herein are provided for consistency with the suggestions under 37 C.F.R. 1.77 or to otherwise provide organizational cues. These headings shall not limit or characterize the invention(s) set out in any claims that may issue from this disclosure. Specifically and by way of example, although the headings might refer to a “Field,” the claims should not be limited by the language chosen under this heading to describe the so-called field. Further, a description of a technology in the “Background” is not to be construed as an admission that certain technology is prior art to any invention(s) in this disclosure. Neither is the “Summary” to be considered as a limiting characterization of the invention(s) set forth in issued claims. Furthermore, any reference in this disclosure to “invention” in the singular should not be used to argue that there is only a single point of novelty in this disclosure. Multiple inventions may be set forth according to the limitations of the multiple claims issuing from this disclosure, and such claims accordingly define the invention(s), and their equivalents, that are protected thereby. In all instances, the scope of the claims shall be considered on their own merits in light of this disclosure, but should not be constrained by the headings set forth herein.
Use of broader terms such as comprises, includes, and having should be understood to provide support for narrower terms such as consisting of, consisting essentially of, and comprised. substantially of. Use of the term “optionally,” “may,” “might,” “possibly,” and the like with respect to any element of an embodiment means that the element is not required, or alternatively, the element is required, both alternatives being within the scope of the embodiment(s). Also, references to examples are merely provided for illustrative purposes, and are not intended to be exclusive.
While several embodiments have been provided in the present disclosure, it should be understood that the disclosed systems and methods may be embodied in many other specific forms without departing from the spirit or scope of the present disclosure. The present examples are to be considered as illustrative and not restrictive, and the intention is not to be limited to the details given herein. For example, the various elements or components may be combined or integrated in another system or certain features may be omitted or not implemented.
Also, techniques, systems, subsystems, and methods described and illustrated in the various embodiments as discrete or separate may be combined or integrated with other systems, modules, techniques, or methods without departing from the scope of the present disclosure. Other items shown or discussed as directly coupled or communicating with each other may be indirectly coupled or communicating through some interface, device, or intermediate component, whether electrically, mechanically, or otherwise. Other examples of changes, substitutions, and alterations are ascertainable by one skilled in the art and could be made without departing from the spirit and scope disclosed herein, and are therefore included within the scope of this disclosure.
This application claims priority under 35 USC §119 to related and co-pending provisional patent application Ser. No. 62/232,994 entitled “Enhanced Washable Mattress Topper” filed Sep. 25, 2015 (with the year anniversary falling on a Sunday, so that this matter is timely filed to claim priority); and also claims priority benefit under 35 USC §120 to co-pending U.S. patent application Ser. No. 14/600,989 entitled “Washable Mattress Topper” tiled Jan. 20, 2015, which claims benefit under 35 USC §120 to U.S. patent application Ser. No. 13/624,525 (now U.S. Pat. No. 8,966,688) entitled “Washable Mattress Topper” filed Sep. 21, 2012, which claims priority under 35 USC §119 to U.S. Provisional Patent Application Ser. No. 61/537,986 filed on Sep. 22, 2011, entitled “Washable Mattress Topper” (such that this present application also claims priority to an effective filing date of Sep. 22, 2011 through U.S. Provisional Patent Application Ser. No. 61/537,986); all of which are hereby incorporated by reference as if reproduced in their entirety.
| Number | Date | Country | |
|---|---|---|---|
| 62232994 | Sep 2015 | US | |
| 61537986 | Sep 2011 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 13624525 | Sep 2012 | US |
| Child | 14600989 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 14600989 | Jan 2015 | US |
| Child | 15276398 | US |
