U.S. patent application number 15/329812 was filed with the patent office on 2017-08-24 for mattress assembly including mattress overlay and multiple covers.
This patent application is currently assigned to Tempur-Pedic Managment, LLC. The applicant listed for this patent is Tempur-Pedic Management, LLC. Invention is credited to Thomas Brisebras, Isabela Dias De Mello Sa, Ida T. Jensen, Kara W. Johnson, Eric Lopez, Elger Oberwelz, Thomas D.C. Overthun, Brent P. Pfister, Martin Schnitzer.
Application Number | 20170238717 15/329812 |
Document ID | / |
Family ID | 55218196 |
Filed Date | 2017-08-24 |
United States Patent
Application |
20170238717 |
Kind Code |
A1 |
Jensen; Ida T. ; et
al. |
August 24, 2017 |
MATTRESS ASSEMBLY INCLUDING MATTRESS OVERLAY AND MULTIPLE
COVERS
Abstract
Mattress assemblies are provided that include a mattress, a
mattress overlay, and a mattress cover that is comprised of a first
cover and a second cover. The first cover includes a top panel, a
bottom panel, and a continuous side panel that collectively define
a cavity and enclose the mattress. The mattress overlay is
positioned atop the mattress and the first mattress cover. The
second cover, which defines a perimeter, is positioned over and is
dimensionally-sized to cover the mattress overlay and at least the
top panel of the first cover. The second cover can then be
connected to the first cover by a fastener that extends along the
perimeter of the second cover.
Inventors: |
Jensen; Ida T.; (Odense,
DK) ; Oberwelz; Elger; (San Francisco, CA) ;
Overthun; Thomas D.C.; (San Francisco, CA) ;
Schnitzer; Martin; (San Francisco, CA) ; Johnson;
Kara W.; (Mill Valley, CA) ; Pfister; Brent P.;
(Lexington, KY) ; Dias De Mello Sa; Isabela; (San
Francisco, CA) ; Brisebras; Thomas; (San Francisco,
CA) ; Lopez; Eric; (San Francisco, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Tempur-Pedic Management, LLC |
Lexington |
KY |
US |
|
|
Assignee: |
Tempur-Pedic Managment, LLC
Lexington
KY
|
Family ID: |
55218196 |
Appl. No.: |
15/329812 |
Filed: |
July 23, 2015 |
PCT Filed: |
July 23, 2015 |
PCT NO: |
PCT/US2015/041655 |
371 Date: |
January 27, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62029871 |
Jul 28, 2014 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A47C 27/001 20130101;
A47C 27/08 20130101; A47C 31/001 20130101; A47C 31/105 20130101;
A47G 9/0246 20130101; A47C 27/10 20130101; A47C 27/053 20130101;
A47C 27/06 20130101; A47C 27/008 20130101; A47C 27/006 20130101;
A47C 27/18 20130101; A47C 27/15 20130101 |
International
Class: |
A47C 27/00 20060101
A47C027/00; A47C 27/08 20060101 A47C027/08; A47C 27/10 20060101
A47C027/10; A47C 27/18 20060101 A47C027/18; A47G 9/02 20060101
A47G009/02; A47C 31/00 20060101 A47C031/00; A47C 27/05 20060101
A47C027/05; A47C 27/15 20060101 A47C027/15; A47C 27/06 20060101
A47C027/06 |
Claims
1. A mattress assembly, comprising: a mattress; a mattress overlay;
and a mattress cover including a first cover having a top panel, a
bottom panel, and a continuous side panel collectively defining a
cavity for enclosing the mattress, a second cover having a top
surface and a bottom surface, the second cover defining a
perimeter, and the second cover positioned over and
dimensionally-sized to cover the mattress overlay and at least the
top panel of the first cover, and a fastener connecting the second
cover to the first cover along the perimeter of the second
cover.
2. The mattress assembly of claim 1, wherein the mattress, the
mattress overlay, or both are comprised of a flexible foam.
3. The mattress assembly of claim 2, wherein the flexible foam is a
visco-elastic foam.
4. The mattress assembly of claim 1, wherein the mattress, the
mattress overlay, or both include one or more air bladders.
5. The mattress assembly of claim 1, wherein the mattress, the
mattress overlay, or both include a plurality of inner springs.
6. The mattress assembly of claim 1, wherein the continuous side
panel can be characterized as including a head panel, a foot panel,
and two opposing side panels.
7. The mattress assembly of claim 6, wherein the second cover is
dimensionally-sized to cover the mattress overlay, the top panel,
and an upper half of each opposing side panel.
8. The mattress assembly of claim 1, wherein the fastener comprises
one or more zippers extending around the perimeter of the second
cover.
9. The mattress assembly of claim 8, wherein the fastener is a
two-way separating zipper.
10. The mattress assembly of claim 1, wherein the second cover
includes an amount of phase change material.
11. The mattress assembly of claim 1, wherein at least the bottom
surface of the second cover includes a water-impervious and
vapor-permeable material.
12. The mattress assembly of claim 1, wherein the first cover, the
second cover, or both the first cover and the second cover are
comprised of a textile.
13. The mattress assembly of claim 1, wherein the first cover, the
second cover, or both the first cover and the second cover are
comprised of a flame-retardant material.
14. The mattress assembly of claim 1, wherein the first cover, the
second cover, or both the first cover and the second cover includes
an indicia indicative of a characteristic of the mattress, the
mattress overlay, or both.
15. The mattress assembly of claim 14, wherein the indicia is a
pattern or a color.
16. The mattress assembly of claim 15, wherein the indicia is a
pattern, and wherein the pattern is positioned on the top surface
of the second cover.
17. The mattress assembly of claim 1, wherein the first cover
further includes a zipper for securing the first cover around the
mattress, the zipper extending around a periphery of the bottom
panel.
18. The mattress assembly of claim 1, wherein the first cover
further includes a brand tag attached to the first cover.
19. A mattress assembly, comprising: a mattress; a first mattress
cover enclosing the mattress; a mattress overlay positioned atop
the mattress and the first mattress cover; a second mattress
defining a perimeter, the second cover positioned over and
dimensionally-sized to cover the mattress overlay and at least the
top panel of the first cover; and a fastener connecting the second
cover to the first cover along the perimeter of the second
cover.
20. A mattress cover, comprising: a first cover having a top panel,
a bottom panel, and a continuous side panel collectively defining a
cavity for enclosing a mattress, a second cover having a top
surface and a bottom surface, the second cover defining a
perimeter, and the second cover dimensionally-sized to be
positioned over and cover a mattress overlay and at least the top
panel of the first cover, and a fastener connecting the second
cover to the first cover along the perimeter of the second cover.
Description
RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional
Application Ser. No. 62/029,871, filed Jul. 28, 2014, the entire
disclosure of which is incorporated herein by this reference.
TECHNICAL FIELD
[0002] The present invention relates to mattress assemblies
including a mattress overlay and multiple covers. In particular,
the present invention relates to mattress assemblies that make use
of a first cover for enclosing the mattress and a second, cover for
covering a mattress overlay and at least a top panel of the first
cover.
BACKGROUND
[0003] To protect a mattress and prevent it from becoming stained,
torn, or otherwise damaged, mattresses are often surrounded by a
mattress cover that completely covers the top, sides, and the
bottom of the mattress. In most mattress covers, a zipper or other
similar fastener is used to enclose the mattress cover on a single
side or around a bottom portion of the mattress. Such mattress
covers are often sufficient for protecting a mattress. However, in
the event that the mattress cover does become stained, torn, or
otherwise damaged, it may be exceedingly difficult to remove the
mattress cover from the mattress and then replace it with a new or
clean mattress cover. Additionally, mattress covers are almost
always made from protective materials, such as plastics and coarse
fabrics that prevent the underlying mattresses from becoming
stained, torn, or otherwise damaged, but that can be irritating or
uncomfortable to the skin of a user that comes into contact with
such a mattress cover.
[0004] In this regard, mattress covers are often covered with a
fitted sheet that completely covers the top of the mattress cover,
the sides of the mattress cover, and a small portion of the bottom
edge of the mattress cover (as a result of a lower edge of the
fitted sheet being tucked under the mattress). Those fitted sheets
typically provide a softer surface on which to rest the body of a
user, and also typically provide a layer of material that can
easily be removed and then cleaned or replaced should the fitted
sheet become stained, torn, or otherwise damaged.
[0005] Nevertheless, it is often the case that fitted sheets slip
off of the mattress cover and the underlying mattress, particularly
when a mattress overlay is being used, and can thus potentially
fail to provide a sufficient additional layer. Moreover, such
fitted sheets are often made from materials that ultimately fail to
protect the underlying mattress cover or mattress overlay as any
staining or damage to the fitted sheet will also typically affect
the mattress cover, mattress overlay, or both. Accordingly, a cover
assembly that can be used with a mattress overlay, and that can be
securely fastened to a mattress, or other support cushion, and
provide a more sufficient layer of protection and functionality
would be both highly desirable and beneficial.
SUMMARY
[0006] The present invention includes mattress assemblies
comprising a mattress overlay and multiple covers. In particular,
the present invention includes mattress assemblies that make use of
a first cover for enclosing the mattress and a second cover for
covering a mattress overlay and at least a top panel of the first
cover.
[0007] In one exemplary embodiment of the present invention, a
mattress assembly is provided that includes a mattress and a first
cover having a top panel, a bottom panel, and a continuous side
panel. The continuous side panel of the first cover can be
characterized as including a head panel, a foot panel, and two
opposing side panels that, with the top panel and bottom panel
collectively define a cavity for enclosing the mattress. The first
cover further includes a brand tag extending vertically along a
portion of the foot panel, as well as a zipper that extends around
a periphery of the bottom panel and is used to secure the first
cover around the mattress.
[0008] The mattress assembly further includes a mattress overlay
positioned atop the top panel of the first cover. Additionally
included in the mattress assembly is a second cover. The second
cover has a top surface and a bottom surface, and also defines a
perimeter. The second cover of the mattress assembly is generally
positioned over the mattress overlay and the top panel of the first
cover and is dimensionally-sized to cover at least the mattress
overlay and the top panel of the first cover. For example, in some
embodiments, the second cover is dimensionally-sized to cover the
mattress overlay, as well as the top panel, the upper halves of
each opposing side panel, an upper edge of the foot panel, and an
upper edge of the head panel of the first cover. By including such
a second cover in an exemplary mattress assembly, the second cover
is thus configured to cover and protect both the mattress overlay
and the portions of the underlying first cover and, consequently,
the portions of any mattress underlying the first cover, that would
be exposed to excessive wear and would be at an increased risk of
becoming stained or damaged. Further, by including such a second
cover in the mattress assembly, the second cover causes the upper
halves of each opposing side panel to assume a more rounded
configuration upon attachment of the second cover to the first
cover.
[0009] With respect to the mattresses and overlays that can be
included in a mattress assembly of the present invention, various
types of mattresses and mattress overlays can be used in accordance
with the present invention including, but are not limited to,
mattresses and mattress overlays comprised of flexible foam,
mattresses and mattress overlays that include a number of inner
springs, mattresses and mattress overlays that include one or more
air bladders (e.g., one or more air bladders contained within a
firm foam shell), and combinations of each of the foregoing.
Regardless of the type of mattresses or mattress overlays included
in an exemplary mattress assembly of the present invention,
however, an exemplary mattress assembly further includes a
fastener, such as a two-way separating zipper, that connects the
second cover to the first cover along the perimeter of the second
cover. By incorporating such a two-way separating zipper into the
mattress assembly, not only can the second cover be easily removed
from the first cover by moving the zipper pulls and slider bodies
in opposite directions and unzipping the second cover from the
first cover (e.g., to clean or replace the second cover), but the
second cover can also be easily reattached to the first cover.
[0010] To further take advantage of the configuration of the second
cover and to provide an increased level of protection to the
mattress overlay and the first cover, as well as any underlying
mattress enclosed by the first cover, the bottom surface of the
second cover can, in some embodiments, also include a
water-impervious and vapor-permeable material that prevents liquids
from traveling through the top surface and the bottom surface of
the second cover into the mattress overlay, the first cover, and
any underlying mattress, but yet allows vapors or moisture in the
first cover or in any underlying mattress to evaporate and travel
though the second cover. In this regard, to provide a first cover
and a second cover that is sufficiently "breathable" and allows
air, heat, and moisture to travel through the mattress assembly,
but yet is also is sufficiently soft and durable, such that the
covers can be easily cleaned and used to help prevent damage to any
portion of the mattress assembly, the first cover, the second
cover, or both are typically comprised of a textile. For example,
in some embodiments, the second cover is comprised of cotton in
order to make the second cover sufficiently-durable and capable of
protecting the mattress overlay and the first cover, but yet
machine-washable and easily cared for, such that the second cover
can be removed from the first cover, cleaned, and then reconnected
to the first cover. In addition to using a textile to provide a
level of protection to an underlying mattress, the first cover and
the second cover also typically incorporate one or more
flame-retardant materials into the first cover and the second cover
to provide a flame-retardant barrier that completely surrounds an
underlying mattress.
[0011] As a further refinement to the mattress assemblies of the
present invention, in some embodiments, an exemplary mattress
assembly also includes a brand tag that is secured to the foot
panel of the first cover. An exemplary mattress assembly can also
include an indicia on either the first cover, the second cover, or
both the first cover and the second cover that is indicative of and
that allows a user to visually identify a characteristic of the
particular mattress and/or mattress overlay included in the
mattress assembly. Such indicia can include patterns, colors, or
combinations of patterns and colors, and can be positioned at a
variety of different locations on the first and second cover.
Regardless of the type or location of the indicia, however, the
indicia is preferably used to indicate a characteristic of the
particular mattress and/or mattress overlay that is included in the
mattress assembly of the present invention. Such characteristics
include, but are not limited to, the firmness or the type of a
particular mattress or mattress overlay that is included. Moreover,
in some embodiments, multiple indicia can be included to indicate
multiple characteristics of a mattress or overlay.
[0012] By placing indicia on the covers of the present invention,
each of the covers described herein can also be used as part of a
method for marking a mattress assembly to allow for visual
identification of a characteristic of a mattress and/or a mattress
overlay. In some implementations, a method for marking a mattress
assembly to allow for visual identification of a characteristic of
the mattress and/or a mattress overlay includes first providing a
mattress assembly having a first cover for enclosing a mattress and
a second cover positioned over and dimensionally-sized to cover a
mattress overlay and at least the top panel of the first cover. The
top surface of the second cover is then marked with a first indicia
that is indicative of a first characteristic of the mattress and/or
the mattress overlay, such that a user can then visually identify a
characteristic of the mattress and/or the mattress overlay by
simply observing the mattress and associating the indicia with the
characteristic (e.g. the firmness or type of the mattress and/or
mattress overlay). In some implementations, a second indicia can
then also be marked on the foot panel of the first cover, the two
opposing side panels, or both the foot panel and the two opposing
side panels, where the second indicia is indicative of either the
first characteristic of the mattress and/or a mattress overlay or
is indicative of a second characteristic of the mattress and/or a
mattress overlay.
[0013] Further features and advantages of the present invention
will become evident to those of ordinary skill in the art after a
study of the description, figures, and non-limiting examples in
this document.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a perspective view of an exemplary mattress
assembly made in accordance with the present invention;
[0015] FIG. 2 is an exploded perspective view of the exemplary
mattress assembly of FIG. 1, showing the second cover removed from
the first cover and positioned over a mattress overlay;
[0016] FIG. 3 is another perspective view of the exemplary mattress
assembly of FIG. 1, showing the second cover partially removed from
the first cover and folded back over the mattress overlay;
[0017] FIG. 4 is a right side elevational view of the mattress
assembly of FIG. 1;
[0018] FIG. 5 is a partial, enlarged right side elevational view of
the mattress assembly of FIG. 1; and
[0019] FIG. 6 is bottom view of the mattress assembly of FIG.
1.
DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0020] The present invention includes mattress assemblies
comprising a mattress overlay and multiple covers. In particular,
the present invention includes mattress assemblies that make use of
a first cover for enclosing the mattress and a second cover for
covering a mattress overlay and at least a top panel of the first
cover.
[0021] With reference to FIGS. 1-6, in one exemplary embodiment of
the present invention, a mattress assembly 10 is provided that
includes a first cover 20 having a top panel 22, a bottom panel 24,
and a continuous side panel 30. The continuous side panel 30 of the
first cover 20 can be characterized as including a head panel 32, a
foot panel 34, and two opposing side panels 36, 38 that, with the
top panel 22 and bottom panel 24, collectively define a cavity for
enclosing a mattress (not shown). The first cover 20 further
includes a brand tag 62 extending vertically along a portion of the
foot panel 34. Also included on the first cover 20 is a zipper 60
that extends around a periphery 25 of the bottom panel 24 and is
used to secure the first cover 20 around a mattress, as best shown
in FIG. 6.
[0022] The mattress assembly 10 further includes a mattress overlay
70 as well as a second cover 40. The second cover 40 has a top
surface 42 and a bottom surface 44, and also defines a perimeter
46. The second cover 40 of the mattress assembly 10 is generally
positioned over the mattress overlay 70 and the top panel 22 of the
first cover 20 and is dimensionally-sized to cover at least the
mattress overlay 70 and the top panel 22 of the first cover 20, the
area of which is indicated by the hatching that is partially shown
in FIG. 2 and that designates a blue color for the top panel 22 of
the first cover 20. In particular, in the mattress assembly 10, the
second cover 40 is dimensionally-sized to cover the mattress
overlay 70, the top panel 22, the upper halves 37, 39 of each
opposing side panel 36, 38, an upper edge 35 of the foot panel 34,
and an upper edge 33 of the head panel 32. By including such a
second cover 40 in the mattress assembly 10, the second cover 40 is
thus configured to cover and protect both the mattress overlay 70
and the portions of the underlying first cover 20 and,
consequently, the portions of any mattress underlying the first
cover 20, that would be exposed to excessive wear and would be, at
an increased risk of becoming stained or damaged, namely the top
panel 22, the upper halves 37, 39 of each opposing side panel 36,
38, the upper edge 35 of the foot panel 34, and the upper edge 33
of the head panel 32. Further, by including such a second cover 40
in the mattress assembly 10, the second cover 40 causes portions of
the mattress overlay 70 and the upper halves 37, 39 of each
opposing side panel 36, 38 to assume a more rounded configuration
upon attachment of the second cover 40 to the first cover 20. Of
course, numerous other sizes and configurations for the second
cover 40 can also be readily selected as desired and can be
incorporated into a particular mattress assembly to prevent damage
or staining to a mattress and/or mattress overlay, or to alter the
appearance of a mattress and/or mattress overlay without departing
from the spirit and scope of the subject matter described herein.
For additional information regarding cover assemblies that
similarly include multiple covers, see, e.g., U.S. patent
application Ser. Nos. 14/145,876, 14/145,863, 14/145,854, and
14/145,867, each of which was filed Dec. 31, 2013, and each of
which is incorporated herein by reference in its entirety.
[0023] With respect to the mattresses and mattress overlays that
can be included in a mattress assembly of the present invention,
various types of mattresses and mattress overlays can be used in
accordance with the present invention and covered by the exemplary
mattress covers described herein. Such types of mattresses and
mattress overlays include, but are not limited to, mattresses and
mattress overlays comprised of flexible foam, mattresses and
mattress overlays that include a number of inner springs,
mattresses and mattress overlays that include one or more air
bladders (e.g., one or more air bladders contained within a firm
foam shell), and combinations of each of the foregoing. For
example, in the exemplary embodiment shown in FIGS. 1-9, the
overlay is comprised of a flexible visco-elastic foam, while the
mattress (not shown) covered by the first cover 20 is an inner
spring mattress.
[0024] With respect to the flexible foams used in the mattresses
and mattress overlays of the present invention, to the extent that
flexible foam is utilized, the mattresses and overlays are
generally comprised of a flexible foam that has a low resilience as
well as a sufficient density and hardness, which allows pressure to
be absorbed uniformly and distributed evenly across the various
mattresses and overlays. Such flexible foams include, but are not
limited to: latex foam; reticulated or non-reticulated
visco-elastic foam (sometimes referred to as memory foam or
low-resilience foam); reticulated or non-reticulated
non-visco-elastic foam; high-resilience polyurethane foam; expanded
polymer foams (e.g., expanded ethylene vinyl acetate,
polypropylene, polystyrene, or polyethylene); and the like.
[0025] With respect to the hardness of the visco-elastic foams used
in certain of the mattresses and flexible foam layers, suitable
visco-elastic foams typically have a hardness of at least about 10
N to no greater than about 80 N, as measured by exerting pressure
from a plate against a sample of the material to a compression of
at least 40% of an original thickness of the material at
approximately room temperature (i.e., 21.degree. C. to 23.degree.
C.), where the 40% compression is held for a set period of time as
established by the International Organization of Standardization
(ISO) 2439 hardness measuring standard. In some embodiments, the
visco-elastic foam can have a hardness of about 10 N, about 20 N,
about 30 N, about 40 N, about 50 N, about 60 N, about 70 N, or
about 80 N to provide a desired degree of comfort and
body-conforming qualities.
[0026] With respect to the density of the visco-elastic foams used
in certain of the mattresses and flexible foam layers, suitable
visco-elastic foams have a density that also assists in providing a
desired degree of comfort and body-conforming qualifies, as well as
an increased degree of material durability. In some embodiments,
the density of the visco-elastic foam used in the mattresses and
overlays is no less than about 30 kg/m.sup.3 to no greater than
about 150 kg/m.sup.3. In some embodiments, the density of the
visco-elastic foam that is used is about 30 kg/m.sup.3, about 40
kg/m.sup.3, about 50 kg/m.sup.3, about 60 kg/m.sup.3, about 70
kg/m.sup.3, about 80 kg/m.sup.3, about 90 kg/m.sup.3, about 100
kg/m.sup.3, about 110 kg/m.sup.3, about 120 kg/m.sup.3, about 130
kg/m.sup.3, about 140 kg/m.sup.3, or about 150 kg/m.sup.3. Of
course, the selection of a visco-elastic foam having a particular
density will affect other characteristics of the foam, including
its hardness, the manner in which the foam responds to pressure,
and the overall feel of the foam, but it should be appreciated that
a visco-elastic foam having a desired density and hardness can
readily be selected for a particular application or assembly as
desired.
[0027] Additionally, it should be appreciated that the
visco-elastic foam used in the mattresses and overlays described
for use with the mattress assemblies of the present invention need
not be comprised of a single piece of visco-elastic foam, but can
be comprised of multiple layers of visco-elastic foam with the
layers having different densities and hardness. For example, in
some embodiments, a visco-elastic foam mattress can be utilized
that includes a lower supporting layer of visco-elastic foam with a
density of about 80 kg/m.sup.3 and a hardness of about 13 N, and an
upper comfort layer of visco-elastic foam with a density of about
35 kg/m.sup.3 and a hardness of about 10 N.
[0028] Regardless of the type of mattresses or mattress overlays
included in an exemplary mattress assembly of the present
invention, and referring still to FIGS. 1-6, the mattress assembly
10 further includes a fastener in the form of a two-way separating
zipper 50 that connects the second cover 40 to the first cover 20
along the perimeter 46 of the second cover 40. As best shown in
FIGS. 4-5, the two-way separating zipper 50 includes two slider
bodies 52a, 52b that are each connected to a zipper pull 53a, 53b.
The zipper pulls 53a, 53b preferably have an increased size
relative to other zipper pulls used for traditional mattress covers
to allow the slider, bodies 52a, 52b to be easily moved along the
perimeter 46 of the second cover 40. The slider bodies 52a, 52b are
also each connected to the track of the two-way separating zipper
50, such that the, slider bodies 52a, 52b can slide around the
track of the zipper 50 and can be used to separate the second cover
40 from the first cover 20 at any desired position along the length
of the two-way separating zipper 50. In this regard, by
incorporating such a two-way separating zipper 50 into the mattress
assembly 10, not only can the second cover 40 be easily removed
from the first cover 20 by moving the zipper pulls 53a, 53b and
slider bodies 52a, 52b in opposite directions and unzipping the
second cover 40 from the first cover 20 (e.g., to clean or replace
the second cover 40), but the second cover 40 can also be easily
reattached to the first cover 20.
[0029] Further, by making use of a two-way separating zipper 50,
the slider bodies 52a, 52b and zipper pulls 53a, 53b can be
positioned on the two-way separating zipper 50, such that the
slider bodies 52a, 52b and zipper pulls 53a, 53b can be hidden from
sight when not in use or can be positioned along the perimeter 46
of the second cover 40 where the risk of the slider bodies 52a, 52b
and zipper pulls 53a, 53b causing damage to the mattress assembly
10, or any underlying mattress, is minimized. For example, the
slider bodies 52a, 52b can be positioned adjacent to a panel of
reinforcing fabric 54 on the perimeter 46 of the second cover 40,
as shown best in FIG. 5. The panel of reinforcing fabric 54 helps
to protect the second cover 40 when a user grabs one or both of the
zipper pulls 53a, 53b and begins to move the slider bodies 52a, 52b
along the track of the zipper 50, but yet also helps to identify
the location of the slider bodies 52a, 52b and zipper pulls 53a,
53b.
[0030] To further take advantage of the configuration of the second
cover 40 and to provide an increased level of protection to the
mattress overlay 70 and the first cover 20, as well as any
underlying mattress enclosed by the first cover 20, and referring
again generally to FIGS. 1-6, the bottom surface 44 of the second
cover 40 can also include a water-impervious and vapor-permeable
material. The water-impervious and vapor-permeable material
included in the bottom surface 44 of the second cover 40 can
include materials such as expanded polytetrafluoroethylene (ePTFE,
e.g., Gore-Tex.RTM., W. L. Gore & Associates, Inc., Newark,
Del.). In this regard, the water-impervious and vapor-permeable
material included in the bottom surface 44 of the second cover 40
thus prevents liquids from traveling through the top surface 42 and
the bottom surface 44 of the second cover 40 into the mattress
overlay 70, the first cover 20, and any underlying mattress, but
yet allows vapors or moisture in the first cover 20 or in any
underlying mattress to evaporate and travel though the second cover
40.
[0031] To provide a first cover 20 and a second cover 40 that is
sufficiently "breathable" and allows air, heat, and moisture to
travel through the mattress assembly 10, but yet is also is
sufficiently soft and durable, such that the covers 20, 40 can be
easily cleaned and used to help prevent damage to any portion of
the mattress assembly 10, the first cover 20, the second cover 40,
or both are typically comprised of a textile. For example, in the
embodiment shown in FIGS. 1-9, the second cover 40 is comprised of
cotton in order to make the second cover 40 sufficiently-durable
and capable of protecting the mattress overlay 70 and the first
cover 20, but yet machine-washable and easily cared for, such that
the second cover 40 can be removed from the first cover 20,
cleaned, and then reconnected to the first cover 20. Of course,
100% cotton materials, as well as numerous other textiles,
including silk and textiles having varying percentages of cotton
can also be readily used in any of the mattress assemblies
described herein and can be selected for a particular mattress
assembly or a particular application or type of mattress as
desired.
[0032] In addition to using a textile to provide a level of
protection to an underlying mattress, the first cover 20 and the
second cover 40 also typically incorporate one or more
flame-retardant materials into the first cover 20 and the second
cover 40. By incorporating a flame-retardant material (e.g., a fire
sock) into the first cover 20, the first cover 20 and the second
cover 40 thus provide a flame-retardant barrier that completely
surrounds an underlying mattress, such as a visco-elastic foam
mattress. Moreover, by incorporating a flame-retardant material
into the second cover 40, the second cover 40 helps to prevent any
flames or heated materials contacting the second cover 40 from
damaging the underlying mattress overlay 70 and the first cover
20.
[0033] As an even further possible addition to the mattress
assembly 10 that increases the comfort of a user, the first cover
20 can further include a charcoal sheet that is incorporated into
the top panel 22 of the first cover 20, and is thus positioned to
eliminate or mitigate the presence of any odors or chemicals
present in or being emitted from the mattress assembly 10 or, in
particular, in a mattress enclosed by the first cover 20. For
instance, in some embodiments, in which the first cover 20 is used
to surround a newly-produced mattress comprised of a flexible foam,
the charcoal sheet provides an effective means to eliminate or
mitigate the gases and odors that are initially present in such
mattresses. Of course, such charcoal sheets can also be
incorporated into a second cover of an exemplary mattress assembly
of the present invention without departing from the spirit and
scope of the subject matter described herein. In addition, although
a charcoal sheet is preferably used in connection with mattress
assemblies of the present invention as it is sufficiently non-toxic
and can readily be incorporated into a cover for a mattress, it is
contemplated that the present mattress assemblies can also readily
incorporate other odor or gas eliminating agents, including more
chemical-based coatings for eliminating odors or gases.
[0034] In yet further exemplary embodiments of the present
invention, the second cover 40 of the mattress assembly 10 can also
include an amount of phase change material incorporated into the
top surface 42 of the second cover 40. The phase change material
that is incorporated into the top surface 42 of the second cover 40
is typically comprised of microspheres that include substances
having a high heat of fusion and that store or release heat as the
substances oscillate between solid and liquid form (i.e., phase
change materials). As the phase change material included in the top
surface 42 of the second cover 40 changes from solid to liquid form
(i.e., melts) as the result of heat generated by a user lying on
the mattress assembly 10, the phase change material thus
continually absorbs heat and provides a cooling effect to the user
until all of the phase change material has been transformed from a
solid to a liquid form. In the top surface 42 of the second cover
40, the phase change material can be incorporated into the top
surface 42 by infusing and coating the top surface 42 of the second
cover 40 with the microspheres of phase change material. However,
it is, of course, contemplated that the phase change material need
not be infused into and/or used to coat only the top surface 42 of
the second cover 40, but could also be infused into and/or used to
coat the bottom surface 44 of the second cover 40, or the top panel
22 of the first cover 20 to provide a sufficient amount of cooling
to the body of a user lying on the mattress assembly 10.
[0035] As a further refinement to the mattress assemblies of the
present invention, the mattress assembly 10 also includes a brand
tag 62 that is secured to the foot panel 34 of the first cover 20.
The brand tag 62 has a size sufficient to display a logo and can be
secured to the foot panel 34 using a variety of means including
glue, hook-and-loop fasteners, stitching, and the like. In some
embodiments, unlike traditional brand tags in which a fabric logo
is sewn to a cover or mattress, the brand tag 62 is typically made
of a sufficiently rigid material (e.g., a plastic) and includes an
interior pocket. In this regard, the brand tag 62 can also be used
to store various materials in the interior pocket that may be
associated with the mattress assembly 10 including, for example,
warranty information for the underlying mattress.
[0036] As an additional refinement to the mattress assemblies of
the present invention, the mattress assemblies can also include an
indicia on either the first cover, the second cover, or both the
first cover and the second cover that is indicative of and allows a
user to visually identify a characteristic of the particular
mattress and/or mattress overlay included in the mattress assembly.
Such indicia can include patterns, colors, or combinations of
patterns and colors, and can be positioned at a variety of
different locations on the first and second cover. For example, the
mattress assembly 10 shown in FIGS. 1-6 includes an indicia in the
form of an interlocking circle pattern 80 that is positioned on the
top surface 42 of the second cover 40.
[0037] Regardless of the type or location of the indicia, as noted,
the, indicia is preferably used to indicate a characteristic of the
particular mattress and/or mattress overlay that is included in the
mattress assembly of the present invention. Such characteristics
include, but are not limited to, the firmness or the type (e.g.,
spring, foam, etc.) of a particular mattress or mattress overlay
that is included. Moreover, in some embodiments, multiple indicia
can be included to indicate multiple characteristics of a mattress
or overlay.
[0038] By placing indicia on the covers of the present invention,
each of the covers described herein can also be used as part of a
method for marking a mattress assembly to allow for visual
identification of a characteristic of a mattress and/or a mattress
overlay. In some implementations, a method for marking a mattress
assembly to allow for visual identification of a characteristic of
the mattress and/or a mattress overlay includes first providing a
mattress assembly having a first cover for enclosing a mattress and
a second cover positioned over and dimensionally-sized to cover a
mattress overlay and at least the top panel of the first cover. The
top surface of the second cover is then marked with a first indicia
that is indicative of a first characteristic of the mattress and/or
the mattress overlay, such that a user can then visually identify a
characteristic of the mattress and/or the mattress overlay by
simply observing the mattress and associating the indicia with the
characteristic (e.g. the firmness or type of the mattress and/or
mattress overlay). In some implementations, a second indicia can
then also be marked on the foot panel of the first cover, the two
opposing side panels, or both the foot panel and the two opposing
side panels, where the second indicia is indicative of either the
first characteristic of the mattress and/or a mattress overlay or
is indicative of a second characteristic of the mattress and/or a
mattress overlay.
[0039] Throughout this document, various references are mentioned.
All such references are incorporated herein by reference, including
the references set forth in the following list:
REFERENCES
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[0072] One of ordinary skill in the art will recognize that
additional embodiments or implementations are possible without
departing from the teachings of the present invention or the scope
of the claims which follow. This detailed description, and
particularly the specific details of the exemplary embodiments and
implementations disclosed herein, is given primarily for clarity of
understanding, and no unnecessary limitations are to be understood
therefrom, for modifications will become obvious to those skilled
in the art upon reading this disclosure and may be made without
departing from the spirit or scope of the claimed invention.
* * * * *