U.S. patent application number 10/702358 was filed with the patent office on 2004-07-22 for mattress and removable mattress cover assembly.
This patent application is currently assigned to Your Design Mattress Factory. Invention is credited to Walters, Robert G. JR..
Application Number | 20040139552 10/702358 |
Document ID | / |
Family ID | 32718178 |
Filed Date | 2004-07-22 |
United States Patent
Application |
20040139552 |
Kind Code |
A1 |
Walters, Robert G. JR. |
July 22, 2004 |
Mattress and removable mattress cover assembly
Abstract
A removable mattress cover assembly includes a removable
mattress cover that attaches to an upright wall assembly. The
upright wall assembly includes an upright wall that attaches to a
top of a mattress base and one or more wall fasteners attached at
or near the top of the upright wall. The removable mattress cover
includes cover fasteners that mate with respective wall fasteners
to attach the cover to the upright wall. When the cover fasteners
are attached to the wall fasteners, the removable mattress cover
lays over the top of the mattress base, and the upright wall is
nearly perpendicular to the removable mattress cover. This allows a
fill material that is nearly the same size as the top of the
mattress to be inserted beneath the removable mattress cover. The
fasteners can project upwardly, away from the top of the mattress
base, making the fasteners easily accessible from above.
Inventors: |
Walters, Robert G. JR.;
(Brunswick, OH) |
Correspondence
Address: |
Renner, Otto, Boisselle & Sklar
19th Floor
1621 Euclid Ave.
Cleveland
OH
44115
US
|
Assignee: |
Your Design Mattress
Factory
|
Family ID: |
32718178 |
Appl. No.: |
10/702358 |
Filed: |
November 6, 2003 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
60440560 |
Jan 16, 2003 |
|
|
|
Current U.S.
Class: |
5/737 ;
5/690 |
Current CPC
Class: |
A47C 27/008 20130101;
A47C 31/105 20130101; A47C 27/005 20130101; A47C 31/007
20130101 |
Class at
Publication: |
005/737 ;
005/690 |
International
Class: |
A47G 009/00; A47C
031/00 |
Claims
1. A removable mattress cover assembly for attachment to a mattress
base, comprising: 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 a 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 cover
fasteners are fastened to the 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.
2. A removable mattress cover assembly as set forth in claim 1,
wherein the upright wall assembly further includes a second row of
a plurality of wall fasteners attached to the upright wall and
spaced below a plurality of fasteners at or near the top of the
upright wall.
3. A combination, comprising: a removable mattress cover assembly
as set forth in claim 1; and a mattress base, wherein the upright
wall is attached to the mattress base.
4. A mattress as set forth in claim 3, wherein the mattress base is
an existing mattress.
5. A removable mattress cover assembly as set forth in claim 1,
wherein when the one or more cover fasteners are fastened to the
one or more all 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.
6. A method of making a mattress, comprising 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 a top of the upright wall; providing a
removable mattress cover including one or more cover fasteners that
mate 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.
7. A method as set forth in claim 6, further including attaching a
second row of a plurality of wall fasteners to the upright wall
spaced below the plurality of fasteners at or near the top of the
upright wall.
8. A method as set forth in claim 6, wherein the mattress base
includes an upright outer wall depending from the top, and wherein
the upright wall is attached to the mattress base in substantially
coplanar relation to the upright outer wall of the mattress
base.
9. A method as set forth in claim 6, further including the step of
inserting a layer of fill material between the top of the mattress
base and the removable mattress cover, the layer of fill material
having substantially the same footprint as the footprint of the top
of the mattress base.
10. A method of retrofitting an existing mattress with a removable
mattress cover, comprising the steps of: attaching an upright wall
to a top of the existing mattress; attaching a one or more of 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 the respective wall fasteners; and fastening the
one or more cover fasteners to respective wall fasteners, whereby
the removable mattress cover covers the top layer of the existing
mattress and the upright wall is substantially perpendicular to the
removable mattress cover.
11. A method as set forth in claim 10, further including attaching
a second row of a plurality of wall fasteners to the upright wall
spaced below the one or more fasteners at or near the top of the
upright wall.
12. A method as set forth in claim 10, wherein the existing
mattress includes an upright outer wall depending from the top, and
wherein the upright wall is attached to the existing mattress in
substantially coplanar relation to the upright outer wall of the
existing mattress.
13. A method as set forth in claim 10, further including the step
of inserting a layer of fill material between the top of the
existing mattress and the removable mattress cover, the layer of
fill material having substantially the same footprint as the
footprint of the top of the existing mattress between the top of
the existing mattress and the removable mattress cover.
14. A mattress, comprising: 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 the respective upper surface fasteners; wherein
when the one or more cover fasteners are fastened to respective
upper surface fasteners, the removable mattress cover covers the
top of the mattress base and the one or more cover fasteners
project upwardly relative to the top of the mattress base.
15. A mattress as set forth in claim 14, wherein the mattress base
is an existing mattress.
16. A method of making a mattress, comprising 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 respective of upper surface fasteners; and fastening
the cover fasteners to respective upper surface fasteners, whereby
the removable mattress cover covers the top of the mattress base
and the one or more cover fasteners project upwardly relative to
the top of the mattress base.
17. A method of retrofitting an existing mattress with a removable
mattress cover, comprising 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 cover fasteners to respective upper surface
fasteners, whereby the removable mattress cover covers the top of
the existing mattress and the one or more cover fasteners project
upwardly relative to the top of the existing mattress.
Description
RELATED APPLICATION DATA
[0001] This application claims the benefit of U.S. Provisional
Patent Application Serial No. 60/440,560, filed on Jan. 16, 2003,
which is hereby incorporated by reference.
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.
* * * * *