Patent Application
20140068868
This description relates generally to bed linens, particularly a unified mattress topper cover and bed cover. More particularly, this description relates to a unified, reversible mattress topper and bed cover combination.
To add desired mattress properties, such as softness, support, etc., to a bedding product, today's consumers often turn to the use of a mattress topper made from a variety of materials. Often the toppers and/or mattresses are covered with a bed cover to protect the underlying topper and mattress or to impart additional properties. Topper covers traditionally are separate from bed covers, and often are just zippered enclosures encasing the topper. The covered topper is then laid on the mattress.
There is a continuing need for enhanced topper properties and for an easy way to change those properties as well as secure the topper to the mattress.
Some embodiments provide a bed linen, comprising a mattress topper cover, itself comprising a first sleep surface comprising a first fabric and defining a first peripheral edge, a second sleep surface comprising a second fabric and defining a second peripheral edge, wherein the first fabric has a different fiber content and/or arrangement of fibers than the second fabric, a gusset extending between the first sleep surface and the second sleep surface along their respective first and second peripheral edges to define a cavity therebetween for receiving a mattress topper; and a skirt affixed at and along substantially the horizontal midline of the gusset for securing to a mattress; wherein the bed linen is reversible by flipping the mattress topper to expose one of the first sleep surface or the second sleep surface and adjusting the skirt in an appropriate direction to cover the mattress.
In some embodiments, one of the first sleep surface or the second sleep surface comprises a heat-dissipating fabric.
In some embodiments, the heat-dissipating fabric is selected from wicking type material, cooling gel, cotton, polyester, nylon, spandex, lycra, polycotton, polyblend, stretch knit, circular knit jacquard, natural fibers such as silk and different cotton blends, including percale, sateen and jersey, and combinations thereof.
In some embodiments, one of the first sleep surface or the second sleep surface comprises a heat-retaining fabric.
In some embodiments, the heat-retaining fabric is selected from velour, wool, flannel, cotton, polyester, wool, microfiber, woven jacquard, plain weave, recycled acrylic, polyamide, polypropylene, natural fibers such as silk and different cotton blends, including percale, sateen and jersey, and combinations thereof.
In some embodiments, the first sleep surface comprises a heat-dissipating fabric and the second sleep surface comprises a heat-retaining fabric.
Some embodiments provide a mattress topper cover and bed cover comprising a mattress topper portion and a bed cover portion. The mattress topper portion comprises: a first sleep surface comprising a first fabric; a second sleep surface comprising a second fabric, wherein the first fabric has a different fiber content and/or arrangement of fibers than the second fabric; and a gusset extending between outer edge portions of the first sleep surface and the second sleep surface, thereby forming a cavity for containing a mattress topper. The bed cover portion comprises a skirt affixed at and along substantially a horizontal midline of the gusset for securing to a mattress. The mattress topper cover and bed cover is reversible by flipping the mattress topper portion to expose one of the first sleep surface or the second sleep surface and adjusting the skirt in an appropriate direction to cover the mattress.
In some embodiments, an opening is provided in one or more of the first sleep surface, the second sleep surface, and the gusset to facilitate insertion and removal of the mattress topper.
In some embodiments, the skirt extends over at least a portion of a bottom surface of the mattress, the skirt further comprising an edge to secure the mattress topper portion and bed cover portion in place on the mattress.
In some embodiments, the skirt is elasticized to form a stretch-to-fit skirt.
In some embodiments, the skirt covers the entirety of the mattress.
Some embodiments provide a mattress topper assembly that includes: a mattress topper cover portion comprising: a first sleep surface comprising a first fabric; a second sleep surface comprising a second fabric, wherein the first fabric has a different fiber content and/or arrangement of fibers than the second fabric; a gusset extending between outer edge portions of the first sleep surface and the second sleep surface, thereby forming a fabric cover for containing a mattress topper; a mattress topper contained within the fabric cover, wherein the mattress topper comprises a first support layer corresponding to the first sleep surface and a second support layer corresponding to the second sleep surface; and a bed cover portion comprising a skirt affixed at and along substantially a horizontal midline of the gusset for securing to a mattress; wherein the mattress topper assembly is reversible by flipping the mattress topper portion to expose one of the first sleep surface or the second sleep surface and adjusting the skirt in an appropriate direction to cover the mattress.
In some embodiments, the first support layer of the mattress topper includes a gel-foam and the second support layer of the mattress topper includes a closed-cell foam.
In some embodiments, the first sleep surface includes a first colored fabric and the second sleep surface includes a second colored fabric, wherein the first colored fabric is a different color than the second colored fabric.
The foregoing and other aspects of the present invention are best understood from the following detailed description when read in connection with the accompanying drawings. For the purpose of illustrating the invention, there is shown in the drawings embodiments that are presently preferred, it being understood, however, that the invention is not limited to the specific instrumentalities disclosed. Included in the drawings are the following Figures:
This invention is not limited to the particular processes, compositions, or methodologies described, as these may vary. The terminology used in the description is for the purpose of describing the particular versions or embodiments only, and it is not intended to limit the scope of the present invention which will be limited only by the appended claims. Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art. Although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of embodiments of the present invention, the preferred methods, devices, and materials are now described. All publications mentioned herein are incorporated by reference in their entirety. Nothing herein is to be construed as an admission that the invention is not entitled to antedate such disclosure by virtue of prior invention.
As used in this document, the singular forms “a”, “an”, and “the” include plural reference unless the context clearly dictates otherwise. Thus, for example, reference to a “foam” is a reference to one or more foams and equivalents thereof known to those skilled in the art, and so forth.
As used in this document, the term “about” means plus or minus 10% of the numerical value of the number with which it is being used. Therefore, about 50% means in the range of 45% to 55%.
As used in this document, the term “comprises or comprising” means includes at least the following but does not exclude others.
The term “distributed” as used in this document includes distributed, spread, immersed, embedded, immersed, saturated, deposited, disseminated, scattered, diffused, infused, dispersed, interspersed, encapsulated or the like.
The term “heat-dissipating” as used in this document includes materials or fabrics that have a cooling effect on the body temperature of a user in contact with the material or fabric.
The term “heat-retaining” as used in this document includes materials or fabrics that have a warming effect on the body temperature of a user in contact with the material or fabric.
The term “foam” as used in this document refers to any type of air filled matrix structures including, without limitation, conventional foam, high resilience foam, latex foam rubber, viscoelastic foam, polyurethane foam, memory foam, slow recovery foam, ground foam, latex foam, reflex foam, continuous foam, hyper-soft resilient foam, hyper-soft high airflow viscoelastic foam such as that disclosed in U.S. Publication No. 2005/0278852, which is hereby incorporated by reference, or the combinations thereof. In some embodiments, the foam may be hyper-soft high airflow viscoelastic foam. In particular embodiments, the foam may be viscoelastic polyurethane foam or memory foam. Memory foam is generally temperature-sensitive, so environmental temperatures or a user's body heat may affect how the foam feels. For example, memory foam responds to a user's body heat and molds around the user, thus the foam may aid in relieving pressure points, preventing pressure sores, improving circulation and the like. Higher density memory foam may mold to a warm human body in a few minutes.
In particular embodiments, the foam may be polyurethane foam created from a formulation comprising an isocyanate, a surfactant, and a polyol blend comprising a vegetable oil polyol as described in U.S. Pat. No. 7,700,661, which is hereby incorporated by reference. In further embodiments, the polyurethane foam may be made from a formulation comprising a polyol blend comprising a petrochemical polyol and a vegetable oil polyol, and an isocyanate blend comprising a 2, 4 toluene diisocyanate (TDI) isomer and a 2, 6 TDI isomer, wherein the ratio of petrochemical polyol to vegetable oil polyol in the polyol blend is about equal to the ratio of the 2, 4 TDI isomer to the 2, 6 TDI isomer in the isocyanate blend, as described in U.S. Pat. No. 7,700,661. In some embodiments, the foam may further include additives such as, without limitation, activators, stabilizers, amines, colorants, dyes, pigments, chain-extending agents, surface-active agents (i.e., surfactants), fillers, and the like.
As used in this document, the term “gel-foam” means a foam comprising gel particles dispersed within. The term “gel” as used in this document means any liquid-extended polymer composition. In some aspects, the gel composition may contain a three-dimensional network of cross-linked molecular chains (gels), or it may merely behave as if it contained such a network (gelloids). The gel of embodiments described in this document may be any liquid-extended polymer or gelatinous composition having a molecular weight and durometer characteristics that allow the gel to deform under load of a typical human, while having a resilience that allows it to rebound into its original shape quickly, such as within one second or less, when the load is removed. Examples of gels used in aspects of the invention include, without limitation, oil-extended triblock copolymer compositions such as that disclosed in U.S. Pat. No. 3,485,787, U.S. Pat. No. 3,676,387, U.S. Pat. No. 3,827,999, U.S. Pat. No. 4,176,240, U.S. Pat. No. 4,259,540, U.S. Pat. No. 4,351,913, U.S. Pat. No. 4,432,607, U.S. Pat. No. 4,492,428, U.S. Pat. No. 4,497,538, U.S. Pat. No. 4,509,821, U.S. Pat. No. 4,709,982, U.S. Pat. No. 4,716,183, U.S. Pat. No. 4,833,193, U.S. Pat. No. 4,942,270, U.S. Pat. No. 5,149,736, U.S. Pat. No. 5,331,036, and U.S. Pat. No. 5,994,450; and thermoplastic elastomer gelatinous compositions such as that disclosed in U.S. Pat. No. 4,369,284, U.S. Pat. No. 4,618,213, U.S. Pat. No. 5,262,468, U.S. Pat. No. 5,508,334, U.S. Pat. No. 5,153,254, U.S. Pat. No. 5,334,646, U.S. Pat. No. 5,239,273, U.S. Pat. No. 5,475,890, and U.S. Pat. No. 5,336,708. Each of the above references is hereby incorporated by reference.
Gel-foams may be made by blending a gel (which would be in particle form, optionally encapsulated with a material to preserve the integrity of the gel while it is suspended in the foam) with a polyol to form a blend. In an alternate embodiment, the gel may be encapsulated before being blended with the polyol. Compositions used for encapsulating the gel may comprise polyol, fabric, plastic, elastomers, thermoplastic materials, or the like. The gel particles may be dispersed and suspended throughout the foam composition.
In some embodiments, a foamed gel may be made by pouring a gel into a mold, mixing in a blowing agent into the gel. Examples of blowing agents include isocyanate, water, nitrogen-based materials, sodium bicarbonate, hydrocarbons, carbon dioxide, or the like.
Some embodiments of the present disclosure include a mattress topper comprising at least one first support layer having distributed material dispersed throughout the first support layer. In some embodiments, the mattress topper further comprises at least one second support layer that is free of the distributed material. In particular embodiments, the distributed material is gel. In some embodiments, the gel is encapsulated. In some embodiments, the gel may be encapsulated using polyol, fabric, plastic, elastomers, thermoplastic materials, or a combination thereof. In some embodiments, the foam is memory foam, viscoelastic polyurethane foam or a combination thereof. In some embodiments, the first support layer comprises gel foam. In some embodiments, the first support layer comprises foamed gel.
For example, distributed material may be encapsulated and blended with the polyol before mixing in other foam ingredients such as isocyanate, blowing agent and additives to form the blend. Compositions used for encapsulating the gel may comprise polyol, fabric, plastic, elastomers, thermoplastic materials, or the like. Suitable thermoplastic materials of embodiments include soft polyvinyl chloride, nylon, polypropylene, polyethylene, fluoropolymers, urethane, copolymers of polyvinyl chloride and vinyl acetate, silicon rubber, and mixtures of polyvinyl chloride and synthetic rubber. The thermoplastic material may also be composed of a composite, such as a woven nylon material with a protective coating of urethane or vinyl. Suitable elastomers include poly(ethylene/butylene), hydrogenated poly(isoprene), hydrogenated poly(butadiene), hydrogenated poly(isoprene+butadiene), poly(ethylene/propylene), hydrogenated poly(ethylene/butylene+ethylene/propylene), polyurethane, polyisoprene, polybutadiene, or the like.
In some embodiments, the method further comprises grinding the encapsulated gel before blending the gel with a polyol. In an embodiment, the polyol and gel may be blended in a high shear blending unit configured for receiving and blending polyol and gel particles and discharging a blend. In a particular embodiment, the gel particles and polyol may be added in a two step process wherein in a first step, a pre-blend of gel particles and polyol is formed and in a second step, the pre-blend is subjected to high shear to form a final blend. In an alternative embodiment, the pre-blending and shearing are performed simultaneously. In particular embodiments, the method of dispersing gel into foam comprises grinding, chopping, or otherwise cutting a slab or block of gel into particles, encapsulating the gel particles to form encapsulated gel particles, and dispersing the gel particles into foam.
Some embodiments relate to a reversible mattress topper cover and bed cover. It will be appreciated from the drawings and the description below that many different arrangements may be used within the spirit and scope of the disclosure contained herein. Some embodiments generally provide a mattress topper cover having at least a first sleeping surface and a second sleeping surface on opposite sides of the topper cover and defining a cavity for receiving a mattress topper therebetween. Each of the first sleeping surface and the second sleeping surface may be provided with a different look and/or feel. For example, one side could be provided with a cool fabric (e.g. heat-dissipating) for warm-weather sleeping while the other side could be provided with a warm fabric (e.g. heat-retaining) for cool-weather sleeping. A peripherally extending side surface defines the sides of a bed cover. The peripherally extending side surface extends from substantially the midline of the sides of the topper cover and substantially around the entire periphery of the topper cover, and extends at least a distance sufficient to wrap around the side of the mattress and at least partially onto the underside of the mattress. The bottom edge may be elasticized to secure the topper cover and bed cover in place. In some embodiments, the side surface may extend into a bottom surface such that substantially the entire bottom surface of the mattress in enclosed. By extending the peripherally extending side surfaces from substantially the midline of the side of the topper cover, the topper cover can be flipped or reversed easily to expose the opposite sleeping surface. The side surfaces can likewise be reversed and still be used to engage the mattress and secure the topper cover in place. In this manner, the consumer can use a single mattress topper and easily switch between two desired properties based on the choice of materials of the two sleeping surfaces.
Although attaching the skirt (i.e., the peripherally extending side surface) at approximately the horizontal midline facilitates easy flipping and reversing, in some embodiments, it is possible to attach the skirt skewed from the midline. In such instances, the sidewall of the skirt should be such that regardless of the topper orientation, the skirt is able to be tucked around and under the mattress so that the topper is secured and the mattress fully protected.
With reference to
As shown in the cross-sectional representation of
From the approximate horizontal midline of sidewall 130 is a side surface, or skirt, 150 extending around substantially the entire periphery of the topper cover portion of the topper cover and bed cover 100 to form a bed cover portion. The side surface 150 can be affixed to the sidewall 130 or formed as an integral part thereof through appropriate fabrication techniques such as sewing, knitting, weaving, bonding, etc. The side surface 150, as depicted in
Arrows A in
As noted above, the two sleeping surfaces 110 and 120 can be different materials (e.g. fabrics) to achieve different properties such as warming (e.g. heat-retaining) or cooling (e.g. heat-dissipating). The two sleeping surfaces 110 and 120 could just as easily be made of the same material, for quick switching, should one of the surfaces become soiled or worn, for example.
In one embodiment, the bed linen includes a mattress topper cover that has a first sleep surface that includes a first fabric and defines a first peripheral edge and a second sleep surface comprising a second fabric and defines a second peripheral edge, wherein the first fabric has a different fiber content and/or arrangement of fibers than the second fabric.
Suitable fibers for either sleeping surface 110 and/or sleeping surface 120 include natural fibers, such as, for example, cotton, silk, wool, and linen; synthetic fibers, such as, for example, polyester, nylon, spandex, lycra, rayon, satin, microfiber, acrylic, recycled acrylic, polyamide, and polypropylene; and combinations thereof, such as, for example, cotton blends, silk blends, wool blends, polycotton, and polyblend. Leather materials are also suitable for use in sleeping surface 110 and/or sleeping surface 120. Suitable arrangements of fibers for either sleeping surface 110 and/or sleeping surface 120 include woven (e.g. percale, sateen, flannel, woven jacquard, plain weave), non-woven, knitted (e.g. stretch-knit, circular knit jacquard, jersey, velour), and crocheted fibers.
In one embodiment, the topper cover and bed cover 100 includes a mattress topper 200 contained within a pocket defined by the two sleeping surfaces 110 and 120. The mattress topper 200 includes one or two support layers. In an embodiment where the mattress topper 200 includes two support layers corresponding to the sleeping surfaces 110 and 120, the two support layers can be different materials to achieve different properties such as heat-retaining in one layer and heat-dissipating in the other layer. In other words, the heat-retaining layer of the mattress topper 200 is in contact with (e.g. corresponds to) the heat-retaining sleeping surface of the topper cover, and the heat-dissipating layer of the mattress topper 200 is in contact with (e.g. corresponds to) the heat-dissipating sleeping surface of the topper cover. Similar to the sleeping surfaces 110 and 120, mattress topper 200 could just as easily be made of one material.
Exemplary heat-retaining materials for use in one or more of the support layers of the mattress topper include closed-cell foams, gel-free-foams, and warming phase change materials such as those disclosed in U.S. Publication No. 2012/019357, which is hereby incorporated by reference. Exemplary heat-dissipating materials for use in one or more of the support layers of the mattress topper include open-cell foams, gel foams, and cooling phase change materials such as those disclosed in U.S. Publication No. 2012/019357, which is hereby incorporated by reference.
In another embodiment, when the two sleeping surfaces 110 and 120 and/or the support layers of the mattress topper 200 corresponding to the sleeping surfaces 110 and 120 are different materials, each sleeping surface 110 or 120 is made from a differently colored material than the other sleeping surface 110 or 120. Each color is used to identify a property of the sleeping surface and/or support layer of the mattress topper 200 with which it is associated. Any color can be used. Furthermore, the manufacturer is free to use any color to define a certain property. In one embodiment, sleeping surface 110 and the support layer of mattress topper 200 which corresponds to sleeping surface 110 are both made from heat-retaining materials; and sleeping surface 120 and the support layer of mattress topper 200 which corresponds to sleeping surface 120 are both made from heat-dissipating materials. In this embodiment, the sleeping surface 110 is, for example, an orange material and the sleeping surface 120 is, for example, a green material to differentiate these properties.
Potential properties and combinations of the two sleeping surfaces 110 and 120, as well as the support layers of mattress topper 200 which correspond to sleeping surfaces 110 and 120, include but are not limited to hot/cold (e.g. heat-retaining/heat-dissipating), firm/soft, scented/unscented, treated/untreated, and others. The desired properties can be achieved through a combination of various materials, for example, different types of material include viscoelastic/viscoelastic with different densities and/or IFDs (indentation force deflections), viscoelastic/polyurethane foam, viscoelastic/polyethylene foam, viscoelastic/reticulated foam, viscoelastic/fiber, polyurethane foam/polyurethane foam, polyethylene foam/polyethylene foam, gel-foam/gel-foam, gel-foam/gel-free-foam (e.g. foam that does not contain a gel in its finished form), polyurethane foam/fiber, polyethylene foam/fiber, each of which may be infused with scent (vanilla, green tea, lavender, chamomile, eucalyptus, etc.) or with a treatment (such as an anti-fungal, antimicrobial, bed-bug replant, etc.).
In some embodiments, one sleeping surface 110 or 120 comprises a material suitable for warm-weather sleeping (e.g. a heat-dissipating fabric), such as, but not limited to, wicking type material, cooling gel, cotton, polyester, nylon, spandex, lycra, polycotton, polyblend, stretch knit, circular knit jacquard, natural fibers such as silk and different cotton blends, including percale, sateen and jersey, and combinations thereof.
In some embodiments, one sleeping surface 110 or 120 comprises a material suitable for cold-weather sleeping (e.g. a heat-retaining fabric), such as but not limited to velour, wool, flannel, cotton, polyester, wool, microfiber, woven jacquard, plain weave, recycled acrylic, polyamide, polypropylene, natural fibers such as silk and different cotton blends, including percale, sateen and jersey, and combinations thereof.
In one embodiment, a topper cover portion having a first sleeping surface 110 and a second sleeping surface 120 is provided having a three inch gusset 130 therebetween. The first sleeping surface 110 includes 260 gsm pin dot velour (80% cotton, 20% poly) with a polypropylene lining. The second sleeping surface 120 is athletic performance material (with moisture wicking capability). The gusset 130 itself is 215 TC polyester microfiber materials. An elasticized skirt 150, approximately seventeen inches in height, is provided about the periphery of the topper cover portion and secured there by stitching.
As a result, a unified topper and bed cover 100 having a cooling surface and a warming surface is provided. Although the unified, reversible topper and bed cover 100 is described herein as providing two different surfaces for sleeping (e.g. warm/cool), it could also simply provide two different aesthetics, having one pattern on one side and a different pattern on the other. As described above, the combinations of topper properties is nearly limitless.
An opening may be provided in one or more of the first sleeping surface 110, the second sleeping surface 120, and the sidewall 130 to facilitate insertion and removal of the topper 200. The opening may be placed in any suitable location, such as along one or more edges, concealed by cording for aesthetic reasons. The opening may be closeable with, for example, a zipper, Velcro, or other fastening mechanism.
Although the present invention has been described with reference to exemplary embodiments, it is not limited thereto. Those skilled in the art will appreciate that numerous changes and modifications may be made to the preferred embodiments of the invention and that such changes and modifications may be made without departing from the true spirit of the invention. It is therefore intended that the appended claims be construed to cover all such equivalent variations as fall within the true spirit and scope of the invention.
This application claims priority to U.S. Provisional Application Ser. No. 61/698,663 filed Sep. 9, 2012, entitled “Unified, Reversible Mattress Topper Cover and Bed Cover,” which is incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 61698663 | Sep 2012 | US |
