Mattress and removable mattress cover assembly

FIELD OF THE INVENTION

[0002] The present invention relates to mattresses and, more particularly, to a removable mattress cover assembly, and a method of fastening a removable mattress cover to a mattress.

BACKGROUND OF THE INVENTION

[0003] Traditionally, mattresses are an expensive, but disposable piece of bedroom furniture. As mattress covers wear, become soiled or torn, or components beneath the cover wear and sag, consumers discard the mattress because the components cannot be easily repaired or replaced. In fact, consumers rarely, if ever, attempt to reconstruct or repair an old mattress with new components.

[0004] Mattress consumers in the marine and recreational vehicle (RV) industry are particularly sensitive to mattress costs because the rigorous environmental conditions to which these mattresses are exposed usually lead to replacing the mattresses more frequently.

[0005] One way to protect a mattress from wear is to use a removable mattress cover. Mattress covers typically cover a top surface of the mattress. Some mattress covers encase the entire mattress, and other mattress covers use straps or other means to hold the mattress cover in place on the mattress. Mattress covers, however, have not been without drawbacks.

[0006] In one particular mattress cover, a type that encases a mattress, a zipper closure on a side panel below the top surface allows the mattress to be inserted into and removed from the mattress cover.

[0007] When a mattress and mattress cover are installed in the berth of a boat, the side walls of the berth block access to the zipper or other device used to hold the cover to the mattress. Consequently, a user must pull and tug the mattress cover top to reach the zipper or release other devices that wrap around and hold the cover to the mattress. This can be very difficult because the user usually must stretch across or lay on top of the mattress cover to get to certain portions of the mattress. Oftentimes, the pulling and tugging on the top of the cover is so burdensome and inconvenient that the user resorts to removing the entire mattress from the berth to get the cover on or off.

[0008] A similar problem arises in home use where a headboard or footboard may make it difficult to apply or remove the cover. Another problem is that some mattress covers limit the thickness of the mattress or the fill material under the mattress cover. This is particularly true when the mattress cover is snug to the top of the mattress, in which case there is little space between the mattress and the mattress cover. In this situation, over-stuffing stresses the fasteners and impairs their ability to hold the cover on the mattress or makes it difficult or impossible to get the mattress into an enclosing-type cover. Even if the user manages to stuff such a mattress into the cover, closing it can be even more difficult. If the cover is not closed, the mattress will work itself out of the cover.

[0009] Another problem with some mattress covers, particularly with a snug-fitting mattress cover, is that the tautness in the cover causes a hammocking effect whereby, for example, a sleeper's trunk sinks lower into the mattress while the mattress pushes up on the arms, legs and head. To reduce the hammocking effect, the user may attempt to ease the tautness at the zipper by removing material from between the mattress cover and the mattress. Of course, this may adversely affect the cushioning properties that the user wants. Thus, the user can be caught in a trade-off between having a desired amount of cushioning with an accompanying hammocking effect or having a less desirable cushioning with less noticeable hammocking.

[0010] Yet another problems that some other mattress covers mask the feel of the inner material in the mattress or between the mattress and mattress cover. In some instances the mattress cover is a quilted material, for example, and the quilted material masks the feel and comfort qualities of the inner material. Some mattresses also suffer from inner material migration, bunching, or buckling when a sleeper lays down on, rolls over on, or gets up from the mattress.

[0011] Conventional mattresses also may be equipped with perimeter gussets or inner attachment devices that, in effect, reduce the area of the sleeping surface. For example, a conventional pillow-top style mattress typically has a three to five inch gusset, or inward V-shape construction that divides the base mattress from a softer “pillow” mounted on top of the base mattress. The gusset or inward V-shape material, in effect, generally precludes inner fill materials from extending to the edge of the mattress. The inner fill material below the mattress cover, typically the material in which the user seeks comfort, is therefore shorter in length and width than the overall length and width of the mattress. Consequently, the actual sleeping area of the mattress is smaller.

[0012] The weight of an additional sleeping partner or a large weight disparity between sleeping partners magnifies these problems.

SUMMARY OF THE INVENTION

[0013] The present invention generally relates to a mattress including a removable mattress cover that is easily attachable and removable from above, and a mattress cover assembly that enables fill material that is substantially the same size as the top of the mattress to be inserted below the removable mattress cover.

[0014] According to one aspect of the invention, a removable mattress cover assembly for attachment to a mattress base includes an upright wall assembly including an upright wall for attachment to a top of the mattress base and one or more wall fasteners attached at or near the top of the upright wall, and a removable mattress cover including one or more cover fasteners that are matable with respective wall fasteners, wherein when the one or more cover fasteners are fastened to the one or more wall fasteners, the removable mattress cover covers the top of the mattress base and the upright wall is substantially perpendicular to the removable mattress cover.

[0015] A second row of a plurality of wall fasteners may be attached to the upright wall and spaced downwardly from the fasteners at or near the top of the upright wall.

[0016] According to another aspect of the invention, a mattress combination includes the removable mattress cover assembly and a mattress base with the upright wall attached to the mattress base. The mattress base may be part of a newly constructed mattress or an existing mattress that is retrofitted with the removable mattress assembly.

[0017] According to another aspect of the invention, there is provided a method of making a mattress, including the steps of providing a mattress base and an upright wall; attaching the upright wall to a top of the mattress base; attaching one or more wall fasteners at or near the top of the upright wall; providing a removable mattress cover including one or more cover fasteners that are matable with respective wall fasteners; and fastening the one or more cover fasteners to respective wall fasteners, whereby the removable mattress cover covers the top of the mattress base and the upright wall is substantially perpendicular to the removable mattress cover.

[0018] The mattress base may include an upright outer wall depending from the top, and the upright wall may be attached to the mattress base in substantially coplanar relation to the upright outer wall of the mattress base. Moreover, a layer of fill material having substantially the same footprint as the footprint of the top of the mattress base may be inserted between the top of the mattress base and the removable mattress cover.

[0019] According to yet another aspect of the invention, there is provided a method of retrofitting an existing mattress with a removable mattress cover that includes the steps of: attaching an upright wall to a top of the existing mattress; attaching one or more wall fasteners at or near the top of the upright wall; providing a removable mattress cover including one or more cover fasteners that are matable with respective wall fasteners; and fastening the one or more cover fasteners to respective wall fasteners, whereby the removable mattress cover covers the top of the existing mattress and the upright wall is substantially perpendicular to the removable mattress cover.

[0020] According to an aspect of the invention, a removable mattress cover assembly for attachment to a mattress base, includes an upright wall assembly including an upright wall for attachment to a top of the mattress base and one or more wall fasteners attached at or near the top of the upright wall; and a removable mattress cover including one or more cover fasteners that are matable with the respective wall fasteners, wherein when the one or more cover fasteners are fastened to respective wall fasteners, the removable mattress cover covers the top of the mattress base and the cover fasteners project upwardly relative to the top of the mattress base.

[0021] According to an aspect of the invention a mattress includes a mattress base; one or more upper surface fasteners attached to a top of the mattress base; and a removable mattress cover including one or more cover fasteners that are matable with respective upper surface fasteners; wherein when the one or more cover fasteners are fastened to the respective upper surface fasteners, the removable mattress cover covers the top of the mattress base and the cover fasteners project upwardly relative to the top of the mattress base.

[0022] According to yet another aspect of the invention, there is provided a method of making a mattress, including the steps of: providing a mattress base; attaching one or more upper surface fasteners to a top of the mattress base; providing a removable mattress cover including one or more cover fasteners that are matable with the respective of upper surface fasteners; and fastening the one or more cover fasteners to respective upper surface fasteners, whereby the removable mattress cover covers the top of the mattress base and the cover fasteners project upwardly relative to the top of the mattress base.

[0023] According to still another aspect of the invention, there is provided a method of retrofitting an existing mattress with a removable mattress cover, including the steps of: attaching one or more upper surface fasteners to a top of the existing mattress; providing a removable mattress cover including one or more cover fasteners that are matable with respective upper surface fasteners; and fastening the one or more cover fasteners to respective upper surface fasteners, whereby the removable mattress cover covers the top of the existing mattress and the cover fasteners project upwardly relative to the top of the existing mattress.

[0024] The present invention comprises a mattress including a removable mattress cover that enables a consumer to easily replace a soiled mattress cover, easily change surface pads, alter the firmness factors, protect the consumer's investment by waterproofing the mattress contents under the cover, or replace components without having to replace the entire mattress. Advantageously, the initial investment in the mattress is extended due to the flexibility in changing or modifying the mattress to individual firmness preferences and needs. The mattress can be one-sided or two-sided. A wide range of end users in the mattress industry, including health care facilities, marine, consumer home use, commercial hotel, antique, and RV market segments, can utilize the mattress according to the present invention.

[0025] The foregoing and other features of the invention are hereinafter fully described and particularly pointed out in the claims, the following description and the annexed drawings setting forth in detail an embodiment of the invention, such being indicative, however, of but one of the various ways in which the principles of the invention may be employed.

BRIEF DESCRIPTION OF DRAWINGS

[0026]
FIGS. 1A & 1B are respective front and back perspective views of an upright wall of an upright wall assembly of a mattress according to an embodiment of the present invention, the upright wall being shown spread laterally outward.

[0027]
FIG. 2 is a perspective view of the upright wall of FIG. 1 sewn around a perimeter of a bottom to form an upright wall assembly, the upright wall assembly and the bottom together forming a cavity for receiving inner fill materials.

[0028]
FIG. 3 is a perspective view of the upright wall assembly of FIG. 2 with a flange sewn around the perimeter of the bottom of the upright wall assembly.

[0029]
FIG. 4 is a bottom perspective view of upright wall assembly of FIG.3.

[0030]
FIG. 5 is a perspective view of the upright wall assembly of FIGS. 3 and 4 sewn to a mattress base, the flange being inward of and adjacent to an upright outer wall of the mattress base.

[0031]
FIG. 6 is a perspective view of a mattress according to an embodiment of the invention, partially exploded to show a removable mattress cover removed from the upright wall assembly.

[0032]
FIG. 7 is a perspective view of a pair of mattresses, each according to an embodiment of the invention, and each similar to the mattress of FIG. 6.

[0033]
FIG. 8 is a perspective view of a mattress according to an embodiment of the present invention, with various layers of the mattress partially folded back.

[0034]
FIG. 9 is a side elevational view of the mattress of FIG. 8, partially broken to show layers of inner fill material.

[0035]
FIG. 10 is an end elevational view of the mattress of FIG. 8.

[0036]
FIG. 11 is a perspective view of a retrofitted existing mattress and a removable mattress cover according to an embodiment of the present invention, the removable mattress cover being shown partially folded back upon itself and partially fastened to the existing mattress.

[0037]
FIG. 12 is a perspective view of a retrofitted existing mattress and a removable mattress cover according to an embodiment of the present invention, the removable mattress cover being shown partially folded back upon itself and partially fastened to the existing mattress.

[0038]
FIG. 13 is a perspective view of a retrofitted existing mattress, an upright wall assembly, and a removable mattress cover according to another embodiment of the present invention, the removable mattress cover being shown partially folded back upon itself.

[0039]
FIG. 14 is a perspective view of the retrofitted existing mattress of FIG. 13, upright wall assembly, and removable mattress cover.

[0040]
FIG. 15 is a perspective view of a retrofitted existing mattress and a removable mattress cover according to an embodiment of the present invention, the removable mattress cover being shown partially folded back upon itself.

[0041]
FIG. 16 is a perspective view of a pair of removable mattress covers and an existing mattress that has been retrofitted on the top and bottom thereof to accommodate the removable mattress covers.

[0042]
FIG. 17 is a perspective view of a retrofitted existing mattress, a pair of upright wall assemblies, and a pair of removable mattress covers, according to an embodiment of the present invention.

[0043]
FIG. 18 is a perspective view of an existing mattress and an upright wall assembly mounted thereto with multiple rows of fasteners according to an embodiment of the present invention.

[0044] In the detailed description that follows, where considered appropriate, reference numerals have been repeated among the figures to indicate corresponding elements, regardless of whether they are shown in different embodiments of the invention. To illustrate the present invention in a clear and concise manner, the drawings may not necessarily be to scale and certain features may be shown in somewhat schematic form. For example, the dimensions of some of the elements are exaggerated relative to each other for clarity.

DETAILED DESCRIPTION

[0045]
FIGS. 1 through 6 illustrate sequential steps of a method of constructing a mattress 10 in accordance with an embodiment of the present invention. In FIG. 6, an exemplary completed exemplary mattress 10 in accordance with the present invention typically includes a mattress base 12, an upright wall assembly 14 and a removable mattress cover 20. The removable mattress cover 20 fastens to an upper surface of the upright wall assembly 14 with one or more suitable fasteners that are easily accessible from above the mattress 10. Therefore, a user can easily detach and reattach the removable mattress cover 20 with respect to the upright wall assembly 14, even within the tight confines of the berth of a boat. Moreover, owing to the construction of the upright wall assembly 14 with respect to the mattress base 12, the removable mattress cover 20 flexes and moves freely, alleviating the hammocking effect exhibited by some prior mattress covers. The user can construct the mattress 10 anew or retrofit an existing mattress to include the mattress cover 20.

[0046] Turning to a more detailed description of the mattress 10, FIGS. 1A,1B and 2 show an upright wall 24 and a bottom or bottom layer 28 of the upright wall assembly 14. FIGS. 1A and 1B show respective outer and inner faces of the upright wall 24 spread laterally outward. The upright wall 24 may be made of any suitable material, for example, a multi-needle quilted material. A thicker material (for example one half inch ({fraction (1/2)}″) polyurethane foam) may additionally or alternatively be used in the upright wall 24 to add durability, wear resistance and longevity. Alternatively, the upright wall assembly 14 can have a conventional border material, generally {fraction (3/16)}″ or {fraction (1/4)}″ thick. An indented reinforcing stitch 30 is serged to both the top and the bottom of the upright wall 24. The bottom layer 28 of the upright wall assembly 14 may be made of any suitable material, for example, a cloth material, or a multi-needle quilted material.

[0047] The upright wall 24 is sewn, for example by a single needle stitch or serging, to the perimeter of the bottom layer 28. This places the upright wall 24 substantially perpendicular to the bottom layer 28. Together, the upright wall 24 and bottom layer 28 form the upright wall assembly 14. As shown in FIG. 2, because the upright wall 24 is stitched to the perimeter of the bottom layer 28 in a relatively perpendicular manner, the upright wall assembly 14 forms a cavity that can receive a fill material, such as a foam material, cotton, fiber, silk or wool, having a peripheral dimension or footprint substantially the same as the peripheral dimension or footprint of the bottom layer 28 of the upright wall assembly 14. Unlike prior mattress assemblies, the upright wall construction is not undulated, interrupted or restricted by perimeter gussets or extra inner attachment devices. Of course, depending on such factors as the stitching or sewing equipment and styles, or the materials used, the upright wall 24 may have some areas that are not perpendicular or at 90 degrees in some portions. In this regard, the term “substantially perpendicular” as used herein means at approximately ninety degrees with respect to the reference surface, or plus or minus about fifteen degrees from vertical. As will be appreciated, the more perpendicular or vertical that the upright wall 24 is relative to the bottom layer 28, the larger the volume of the cavity of the upright wall assembly 14.

[0048] In the illustrated embodiment, the bottom layer 28 of the upright wall assembly 14 also functions as a top layer of the mattress base 12. As further described below, the bottom layer 28 may alternatively be independent of and lie adjacent to an already-existing top layer of a mattress base or existing mattress. The top layer of the mattress base or mattress may be reinforced by serging with an inner reinforcing stitch followed by a 1{fraction (1/4)}″ edging sewn to its perimeter.

[0049] Referring to FIGS. 3 and 4, a flange 32 is stitched at the perimeter of the bottom layer 28 and extends away from the upright wall 24. The flange 32 may be made of any suitable material, for example, cotton, synthetic fibers, non-woven fibers, polyester, or even a tick material having a cotton-polyester blend. A serge stitch may be used to reinforce the flange attachment to the upright wall assembly 14.

[0050] The flange 32 attaches the upright wall assembly 14 to the mattress base 12. As shown in FIG. 5, the mattress base 12 includes an upright outer layer or wall 38 made of, for example, a quilt material, and an inner fill material such as foam (not shown). Although not specifically shown in FIG. 5, the flange 32 is attached inward of and adjacent to the upright outer layer 38. The flange 32 attaches to the inner fill material by a suitable connecting element, for example, glue, hooks and loops, and hog rings. The flange 32, or portions thereof, may be stitched to the upright wall layer 38, to reinforce same.

[0051] Alternatively, the flange 32 may extend outside the upright outer layer 38 of the mattress base 12, in which case the upright outer layer 38 of the mattress base 12 attaches to the inner fill material and the upright outer layer 38 attaches to the flange 32. The upright wall assembly 14 may be connected to the mattress base 12 by means other than by the flange 32, for example, by stitching the bottom of the upright wall 24 of the upright wall assembly 14 directly to the mattress base 12. In another alternative, the flange 32 forms the upright outer layer 38 of the mattress base 12; that is, the flange 32 and upright outer layer 38 are the same component.

[0052] When the upright wall assembly 14 is attached as shown in FIG. 5, the upright wall 24 is substantially coplanar with respect to the upright outer layer 38 of the mattress base 12. In addition, since the upright wall 24 is in a relatively perpendicular to the bottom layer 28 of the upright wall assembly 14, and generally the top layer of the mattress base 12, the upright wall assembly 14 forms a cavity that is capable of receiving a fill material having a peripheral dimension or footprint substantially the same as the peripheral dimension or footprint (as defined by the upright outer layer 38) of the mattress base 12.

[0053] In any of the embodiments, any sewn or stitched material may be reinforced, for example by serging. For example, in one embodiment, a reinforcing stitch serges the upright wall 24 to the mattress base 12. Or, a tape edge material serges corner stitches of the mattress base 12 to reinforce same. Still further, a 1{fraction (1/4)}″ wide tape edge material, for example, may be used to reinforce the perpendicular upright wall 24 and the upright outer layer 38 of the mattress base 12, such as at spaced attachment points, to reinforce same.

[0054] Referring now to FIG. 6, removable means for attachment, including one or more wall fasteners 50, for example, a plurality of snap fasteners, are affixed at or near an upper portion of the upright wall assembly 14. A durable tape edge material, such as polyester, vinyl or nylon fabric may be serged to the upper portion before attaching the wall fasteners 50 to provide additional support for the wall fasteners 50 and to reinforce the upright wall 24.

[0055] Referring briefly again to FIG. 5, a pair of adhesive strips 54 are adhered to the bottom layer 28 of the upright wall assembly 14. The adhesive strips 54 hold an inner foam material or other suitable fill material 58 inside the cavity of the upright wall assembly 14, as is illustrated in FIG. 6. Any suitable adhesive may be used, for example, double sided adhesive tape, hooks and loops, and/or glue. As will be appreciated, the quantity, type and positioning of the adhesive strips 54 will facilitate the manner by which the adhesive strips 54 hold the fill material 58 inside the cavity. For example, if it is desired that the center of the fill material 58 have greater freedom to shift, then the adhesive strips 54 may be positioned at the perimeter of the bottom layer 28. Alternatively, if it is desired that the perimeter of the fill material 58 have greater freedom to shift, then the adhesive strips 54 may be positioned at the center of the bottom layer 28. Other combinations are possible, as will be appreciated.

[0056] The removable mattress cover 20 covers the cavity provided by the upright wall assembly 24. The removable mattress cover 20 may comprise one or more of many combinations of tickings with properties that are waterproof, vinyl, cloth, exotic blends, fire retardant, anti-flammable, hypo-allergenic, anti-fungal, anti-bacterial, cotton, wool, polyester, leather and blends, combinations, and other materials common to the mattress or upholstery industry, depending on the intended use and aesthetics. Additionally, the removable mattress cover 20 may be a smooth top or multi-needled quilted with many different materials or combinations or percentage mixes of cotton, wool, silk, leather synthetic fibers, foam with different densities, I.L.D.'s, and thicknesses or convolutions, and “zoned” cuts, and styles common to the industry such as latex, visco-elastic or polyurethane foam, depending on firmness factors, aesthetics, and other concerns.

[0057] The removable mattress cover 20 includes one or more cover fasteners 60, for example snap fasteners, corresponding to the wall fasteners 50 of the upright wall assembly 24. As shown in FIG. 6, the cover fasteners 60 attach to the removable mattress cover 20 at or near the perimeter thereof and face or project upwardly relative to the top surface of the removable mattress cover 20. It will be appreciated that the removable mattress cover 20 may be reinforced by serging with an inner reinforcing stitch followed by a 1{fraction (1/4)}″ edging sewn to its perimeter.

[0058] The cover fasteners 60 fasten to the respective wall fasteners 50 thereby to secure the removable mattress cover 20 to the upper portion of the upright wall assembly 14. As a result, the fill material 58 is sandwiched between the removable mattress cover 20 and the mattress base 12.

[0059] As shown in FIG. 6, when fastened to the upright wall 24 the removable mattress cover 20 is substantially perpendicular to the upright wall 24 and the cover fasteners 60 thereof project upwardly with respect to the top layer of the completed mattress. As further described below, the upward projection of the cover fasteners 60 makes them more easily accessible from above.

[0060] As will be appreciated, the mattress shown in FIG. 6 has an unusual shape compared to a conventional mattress. Following is a description of alternative embodiments of mattresses and removable mattress cover assemblies having a generally more conventional rectangular shape. It will further be appreciated that the claimed invention contemplates any size mattress, for example, king, queen, twin, and any shape mattress, for example, rectangular, non-rectangular, round, oval, triangular, or heart-shape.

[0061]
FIG. 7 shows a pair of mattresses 62 in accordance with the present invention, each being similar to the mattress 10 of FIG. 6, except larger and rectangularly shaped. In this and each of the later described embodiments of the present invention like reference numerals correspond to like components, and superfluous description in this regard is omitted.

[0062] Each mattress 62 includes a removable mattress cover 64 in accordance with the present invention. A plurality of cover fasteners 60 attach to the perimeter of the removable mattress cover 64. The wall fasteners 50 on an upper rim portion of the mattresses 62 fasten to respective cover fasteners 60, thereby fastening the removable mattress cover 64 to the upright wall assembly 68. As is shown in FIG. 7, the two mattresses 62 are positioned in abutting relation with respect to one another. The cover fasteners 60 project upwardly with respect to the top layers of the mattresses 62, and more particularly the top surfaces of the removable mattress covers 64. Advantageously, even with the mattresses 62 arranged in abutting relation, the cover fasteners 60 are unrestricted and easily accessible from atop the mattresses 62. In tight quarters such as the berth of a boat, this easy accessibility to the cover fasteners 60 in accordance with the present invention simplifies detachment and reattachment, or replacement, of the removable mattress cover 64.

[0063] FIGS. 8-10 show another embodiment of a mattress 80 in accordance with the present invention. The mattress 80 includes a removable mattress cover 82 (for example, a tick layer), a first foam layer 84, and a second foam layer 86. In FIG. 8, the removable mattress cover 82, the first foam layer 84, and the second foam layer 86 are shown partially folded back upon themselves. The second foam layer 86 adheres to the bottom layer 28 of the upright wall assembly 94 of the mattress 80 via the adhesive strips 54. As will be appreciated, adhesive strips 54 may also be disposed between the first and second foam layers 84 and 86, or between the removable mattress cover 82 and the first foam layer 84, as may be necessary or desired to effect a different feel in the fill materials.

[0064] A plurality of cover fasteners 60 are attached to the perimeter of the removable mattress cover 82, and a plurality of wall fasteners 50 matable with the cover fasteners 60 are attached to the upper rim portion of the upright wall assembly 94. FIGS. 9 and 10 show the removable mattress cover 82 fastened to the upright wall assembly 94 via the cover fasteners 60 and mating wall fasteners 50.

[0065] As the mattress 80 demonstrates, the removable mattress cover 82 and the upright wall assembly 94 allow the firmness level to be adjusted by layering the fill material. As will be appreciated, the firmness level can be adjusted by adding or removing fill material, as desired, to meet the specific needs of an individual, for example, extra firm, firm, medium firm, plush firm, soft. Also, as technology and products progress, new products with different properties can be inserted into the cavity of the upright wall assembly 94. The removable mattress cover 82 also enables different levels of firmness in different areas or sections to accommodate the personal preferences of different sleepers. For example, multiple different fill materials can be positioned in laterally adjacent sides of the fill cavity. The fill material can also provide zone-different firmness levels for support at specific targeted areas where desired along the body length, such as lumbar support, for example. The cavity can be filled with new sleep products as technology advances, offering new comfort levels and “feels.”

[0066] As was alluded to above, the present invention is not limited to a new mattress incorporating a removable mattress cover assembly. The concepts of the present invention may also be applied to existing or “used” mattresses. FIGS. 11 and 12 each show an exemplary embodiment of the present invention in which an existing mattress 100 and 102 has been retrofitted to accommodate a removable mattress cover 104. In the FIGS. 11 and 12 embodiments, there is no upright wall assembly in which wall fasteners are secured. Instead, a plurality of upper surface fasteners 108 attach at or near the perimeter of the existing mattress 100 in the top layer thereof as shown. In the FIG. 11 existing mattress 100, the upper surface fasteners 108 are attached as by stitching to the top layer of the existing mattress 100. The upper surface fasteners 108 may be attached to an inner structural element of the existing mattress 100 to provide further support thereto. In the FIG. 12 existing mattress 104, the upper surface fasteners 108 are attached to a tape edge material at the perimeter of the existing mattress 102. In the existing mattresses 100 or 102, the cover fasteners 60 fasten to the corresponding mating upper surface fasteners 108 thereby to fasten the removable mattress cover 104 to the existing mattress 100 or 102.

[0067] The mattresses 100 and 102 realize several advantages, particularly in the marine and RV industry. In the marine and RV industry, the cover of a mattress is exposed to an extraordinary amount of wear due to, for example, temperature and humidity fluctuations, sunlight, moisture, and other environmental factors to which household mattresses may not be exposed. Meanwhile, however, the innards of the mattress, for example the fill material or the inner support structure, remain able to function in substantially the same manner as they did when new. Consequently, by being able to retrofit the existing mattress of the marine or RV user with a removable mattress cover in accordance with the present invention, there is no need to purchase a new mattress each time the cover wears. Moreover, as with the earlier described mattresses, the removable mattress cover 104 is easily accessible from the top surface thereof.

[0068]
FIGS. 13 and 14 show another embodiment of an existing mattress 120 that has been retrofitted with a removable mattress cover 124. Here, an upright wall assembly 130 is attached to the existing mattress 120. The upright wall assembly 130 includes an upright wall 132 and a zipper 136 stitched or otherwise attached to the upper rim portion of the upright wall 132. The upright wall assembly 130 is attached to the existing mattress 120 in a manner such as that described above with respect to the FIG. 6 embodiment in which the mattress is constructed anew. In this regard, the bottom of the upright wall 132 is attached directly to the top of the upright outer layer 140 of the existing mattress 120. Additionally or alternatively, a bottom layer (not shown) of the upright wall assembly 130, similar to the previously described bottom layer 28 (FIGS. 2-4), may be juxtaposed with respect to a top layer 142 of the existing mattress 120. Such bottom layer 28 may provide, for example, a suitable surface to which to apply an adhesive, especially if the top layer 142 of the existing mattress 120 is not so suitable. Alternatively, a flange (not shown) of the upright wall assembly 130, similar to the previously described flange 32, can be attached as by stitching to the upright outer layer 140 of the existing mattress 120 either interiorly or exteriorly thereof. As will be appreciated, if the flange is attached on the inside of the upright outer layer 140, the upright outer layer 140 must be detached to some extent from the top layer of the existing mattress 120. As will further be appreciated, if the flange is attached to the exterior of the upright outer layer 140, the flange material may be selected to have a pattern similar to that of the upright outer layer 140 of the existing mattress 120, or to that of another decorative pattern.

[0069] A zipper 146 is stitched or otherwise attached at or near the periphery of the removable mattress cover 124, as is illustrated. Although not shown, an adhesive adheres to the top layer 142 of the existing mattress 120. A suitable fill material 148 such as the illustrated foam layer is then inserted into the cavity provided by the upright wall assembly 130, with the adhesive holding the foam layer therein. The zipper 146 engages the zipper 136 thereby to secure the removable mattress cover 124 to the existing mattress 120.

[0070] As can be seen in FIG. 13, the upright wall 132 is useful for enveloping the perimeter of the fill material 148 inward of the upright wall 132. In the illustrated embodiment, the thickness of the fill material 148 is less than the height of the adjacent upright wall 132. This reduces stress on the zipper fastening system as compared to overly snug prior art mattresses and mattress covers. It will be appreciated that the thickness of the fill material 148 may alternatively be the same as or greater than the height of the upright wall 132. As is shown in FIG. 14, the zipper 146 is easily accessible from the top of the retrofitted existing mattress 120.

[0071]
FIG. 15 shows another embodiment of the present invention in which an existing mattress 160 has been retrofitted to accommodate a removable mattress cover 164. In this embodiment, upper surface loop-and-hook fasteners 168 are secured at or near the perimeter of the top layer of the existing mattress 160, and mating loop-and-hook fasteners 172 are secured to the underside and at or near the periphery of the removable mattress cover 164 as illustrated. The loop-and-hook fasteners 168 and 172 can be attached to the respective top layer of the existing mattress 160 and the underside of the removable mattress cover 164 in any suitable manner, as by stitching for example. The loop-and-hook fasteners 172 engage the loop-and-hook fasteners 168 to secure the removable mattress cover 164 to the existing mattress 160.

[0072] The removable mattress cover assembly need not be limited to one side of the mattress base or existing mattress, and the claimed invention contemplates removable mattress cover assemblies on both sides of mattress. FIG. 16 shows an existing mattress 180 and a pair of removable mattress covers 182 fastened thereto in accordance with an exemplary embodiment of the present invention. The removable mattress covers 182 are similar in construction to the removable mattress cover 104 shown in FIG. 11, for example. A plurality of fasteners 184 are attached to the existing mattress 182 at the top and bottom thereof in a manner similar to the fasteners 108 in the existing mattress 100 shown in FIG. 11, for example. The removable mattress covers 182 are each provided with corresponding mating fasteners 186. Advantageously, the pair of removable mattress covers 182 enable two mattress types, for example, firm or soft, to be incorporated into one mattress assembly.

[0073]
FIG. 17 is a perspective view of an exemplary combination of a retrofitted existing mattress 200, a pair of upright wall assemblies 202, and a pair of removable mattress covers 204 in accordance with the present invention. The existing mattress 200 is retrofitted with the upright wall assemblies 202 in a manner similar to that described above with respect to the upright wall assembly 130 and the existing mattress 120 shown in FIGS. 13 and 14. Here, however, a plurality of wall fasteners 208, for example, the illustrated snap fasteners, are attached to the upper rim portion of the upright wall assemblies 202. In a similar manner, a plurality of cover fasteners 218 are attached at the perimeters of the removable mattress covers 204. The cover fasteners 218 are fastened to the wall fasteners 208 fasten the removable mattress covers 204 to opposite sides of the existing mattress 200. Suitable inner fill materials (not shown) are inserted between the existing mattress 200 and the respective removable mattress covers 204. As will be appreciated, the top and bottom upright wall assemblies 202 may be the same or different, for example, with respect to height and thickness. Similarly, the inner fill materials may be different on opposite sides of the existing mattress 200, as may be necessary or desired.

[0074] Referring now to FIG. 18, there is shown yet another retrofitted existing mattress 230 and an upright wall assembly 232 according to the present invention. In this embodiment, a plurality of fasteners are attached at an upper rim portion 240 of the upright wall 236, at a lower rim portion or row 242 of the upright wall 236, and at an intermediate portion 241. A removable mattress cover with corresponding mating fasteners (not shown), such as the removable mattress cover 64 illustrated in FIG. 7, can be adjustably attached to the upright wall assembly at different heights corresponding to different fastener rows to accommodate, for example, different thicknesses or quantities of fill materials. As will be appreciated, any number of rows of fasteners may be incorporated into the upright wall assembly 232, and the claimed invention contemplates as many as the upright wall 236 can accommodate. Also, it will be appreciated that the upright wall 236 need not necessarily be perpendicular or substantially perpendicular to accommodate multiple rows of fasteners. That is, the upright wall 236 may taper outwardly with respect to the upright outer layer 248 of the existing mattress 230. Moreover, multiple rows of fasteners may be provided in a mattress or retrofitted existing mattress embodying upper and lower upright wall assemblies. As will further be appreciated, if a row of fasteners is not used, the upright wall 236 may be folded downward back over itself. The folded down portion can then be covered by the removable mattress cover fastened to the next lower row of fasteners in the upright wall assembly 232.

[0075] As will be appreciated, the present invention realizes several benefits. The removable mattress cover assembly can be made part of any newly constructed mattress or be retrofitted into any existing mattress in any on-site location, for example, a home, a hotel, a business, a camper, a boat, or a health care facility. Existing mattresses with stained or torn covers may be retrofitted with the removable mattress cover assembly in a matter of minutes. Indeed, no new mattress product purchase is required in order to install the removable mattress cover assembly.

[0076] Moreover, in a marine environment berth where space is usually tightly confined by three side walls, a mattress or retrofitted existing mattress according to the invention can be sized to actually touch the multiple sides of the sleeping berth. The removable mattress cover is conveniently attachable and detachable at the top of the perimeter of the upright wall assembly. Advantageously, the removable mattress cover can be fastened to the mattress or retrofitted existing mattress while an individual is physically on top of the mattress, thus eliminating the need to completely remove the mattress from the berth to gain access to the fasteners below the mattress top layer or surface, as was the case in the prior art.

[0077] For home use, the product is easier for headboard and footboard installation that heretofore has been an obstacle or barrier to fastener access. Removal and installation also are simplified because the upright wall of the upright wall assembly is flexible and can move a few inches in a standard sized mattress towards or away from the top layer perimeter, allowing some “play,” and thus avoiding the need to pull and tug the top layer to get beneath it to access the fasteners. The top layer heretofore was not easily accessible, particularly in a marine or RV environment.

[0078] The removable mattress cover can be installed regardless of the fill material thickness beneath the cover surface, as the upright wall assembly will naturally adjust to increased or decreased thickness. Known past products are limited by thickness restrictions. In prior art mattresses, overstuffing occurred and resulted in excess stress on the perimeter fasteners or attachments, rounding of the mattress cover, or excess tension at the fasteners or attachments. The upright wall assembly in accordance with the present invention reduces the likelihood or prevents such stress at the perimeter fasteners and attachments, and reduces or prevents rounding of the removable mattress cover.

[0079] It will be appreciated that multiple styles of the mattress or retrofitted existing mattress are possible, including for example conventional sized mattresses, a pillow top mattress, a one-sided, or two-sided mattress, depending on, for example, particular application and demand. Also, different shapes can be produced including regular or non-rectangular shapes, including round, oval, triangle, square, heart, or other shaped mattresses. The removable mattress cover according to the present invention can be easily duplicated and reproduced, replaced, removed and cleaned or modified. Due to its simple design, especially difficult shapes having inside corners or indentations such as common boat mattresses or antique four post beds can be made without undue stress on closing seams and attachment materials.

[0080] Free and unrestricted movement of the upright wall of the upright wall assembly yields a “pillow top posturizing effect” that allows the removable mattress cover to adjust to differences in body weight, body positions, or different sleeping partners. The removable mattress cover assembly reduces the “hammock effect” experienced by covers secured or held in place at relatively lower positions, which cannot move or respond to different pressures.

[0081] The upright wall assembly in accordance with the present invention enables mobility of the inner fill material, such as foam material, and the ability for the inner fill material to conform, respond, and adjust to pressure areas. Heretofore, quilt covers were used to cover the inner foam material, which masked the actual feel, comfort qualities and benefits of the inner foam material, so that the user felt the quilt material instead or more so. The removable mattress cover assembly of the present invention alleviates this problem by providing a removable mattress cover that need not necessarily be a quilted cover, but rather any suitable material cover to take advantage of the benefits of the inner fill material underneath. In this regard, the removable mattress cover may be made of any suitable material, for example, 180 percale sheet material, 200 percale, or 300 percale, a center 1 oz. fiber or {fraction (1/2)}oz. fibre. A bottom sheet with 180, 200, 300 percale may be multi-needle quilted to an upper sheet to form the removable mattress cover. Such materials allow instant feel of materials beneath the removable mattress cover. Inner fill materials beneath the removable mattress cover need not be sewn, allowing the materials to react as designed without sewing tension restrictions. As will be appreciated, the removable mattress cover can be made of conventional quilted layers and fill material or non-quilted materials, it being understood that the claimed invention contemplates a removable mattress cover that is flexible and removable with respect to an upright wall assembly or a top layer of a mattress base or a retrofitted existing mattress.

[0082] Two exemplary materials that may be used to accentuate the “feel” of the inner fill materials include, for example, visco-elastic material (for example two inches thick) or memory foam. The upright wall and removable mattress cover move and adjust in response to movement and adjusting in the memory foam. Together the upright wall, removable mattress cover and memory foam adjust and conform to body weight, and work together to fully utilize the memory foam properties without restrictions. In another embodiment, the inner fill material may constitute a soft latex foam. Such product yields or reacts in a similar parallel manner as the removable mattress cover adjusts when body weight is applied. The soft latex or memory foam conforms to pressure, filling in all body curves from wrists, elbows, back, knees, and ankles to distribute the body weight more evenly and disperse body surface pressure.

[0083] The upright wall assembly also permits materials used beneath the removable mattress cover to be wider and/or longer, increasing the actual sleeping area surface, because the upright wall construction is not undulated, interrupted or restricted by perimeter gussets or extra inner attachment devices as in the prior art.

[0084] The adhesive strips installed on the top layer of the mattress base, the top layer of the retrofitted existing mattress, or the bottom layer of the upright wall assembly, as the case may be, prevent or at least reduce the likelihood of the inner fill materials from migrating, bunching, or buckling during entry position, turning, and exiting. The upright wall assembly reduces unnecessary additional seams, thereby reducing thread skips and separation during normal wear and use. Stress points also are reduced due to free movement of the upright wall of the upright wall assembly.

[0085] Although the invention has been shown and described with respect to certain preferred embodiments, it is obvious that equivalent alterations and modifications will occur to others skilled in the art upon reading and understanding this description and accompanying drawings. The present invention includes all such equivalent alterations and modifications and is limited only by the scope of the following claims.

Mattress and removable mattress cover assembly

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