Flame-resistant mattress rejuvenator
A mattress add-on is placed on top of an existing mattress and provides a rejuvenated fire-safe mattress. The mattress add-on has a flame-resistant covering that fits tightly over the sides of the existing mattress and also has flaps to cover the bottom of the existing mattress. The mattress add-on in combination with the flame-resistant covering is an inexpensive means of providing both more comfort as well as fire protection safety to consumers who retain their existing mattresses. The mattress add-on does not slip on the existing mattress because it is held tightly in place by tightening the flame-resistant covering using straps across the bottom of the existing mattress. The mattress add-on is customized to a user's physical profile by using zones of foam having different densities. In addition, the mattress add-on may include metal coils or air chambers.
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The present invention relates generally to mattresses, and more particularly to a method of rejuvenating an existing mattress and rendering the existing mattress flame resistant.
BACKGROUNDNew types and forms of mattresses and mattress accessories continue to be developed for traditional bedroom use, as well as for such diverse uses as camping, boating and recreational vehicle traveling. Where developments continue to emerge, consumers may expect to spend considerable sums to upgrade their mattresses and to benefit from those developments. Not all consumers, however, have the means to spend thousands of dollars on their beds.
Memory foam was originally developed for NASA in the 1970's. Since the early 1990's, memory foam has been used in commercially available mattresses. Mattresses that include memory foam, however, can be more expensive than mattresses made of other types of foam. Mattress toppers that include memory foam have allowed consumers to enjoy many of the benefits of memory-foam mattresses without having to purchase entirely new mattresses. However, while memory-foam mattress toppers do provide some ability for consumers to upgrade, these mattress toppers are not without their attendant drawbacks.
One such drawback is the limited ability of some foam products to breathe. As may be appreciated, foam mattresses are typically produced from polymeric compounds. For example, memory foam is made from polyurethane with additional chemicals that add to its viscosity. And in contrast to regular polyurethane foam, memory foam has more open cells that allow air to pass to adjoining cells, for example, when a person lies down on a memory foam mattress. Sleeping on polymeric compounds, however, is not unlike sleeping on a plastic tarp. Users of foam mattresses may complain that their sleep is impaired due to excessive moisture accumulation as a result of sleeping on a non-breathable mattress.
In some instances, a simple cover made of terry cloth or some other natural fiber weave may be implemented to address those concerns. A simple cover may still not, however, allow sufficient ventilation to achieve a cool sleep environment. The simple cover may not absorb all of the perspiration that accumulates during the hot sleeping period. Moreover, a simple cover may not hold the mattress topper in place on the existing mattress. Thus, the mattress topper may skew inside the cover leaving uncomfortable and unsightly wrinkles. Finally, conventional mattress toppers are not generally customized to a user's particular physical profile. Some air mattresses, for example, can be customized by selecting the air pressure that is pumped into various air chambers. Foam mattress toppers, however, may lack this ability to be customized, leaving a user only to select a best average foam density for the topper.
Although a consumer obtains some of the benefits of a memory-foam mattress without having to purchase an entirely new mattress by purchasing a memory-foam mattress topper, the consumer nevertheless retains at least one significant disadvantage of his existing mattress, namely its vulnerability to catching on fire. A newly purchased mattress is likely to be flame resistant. Simply placing a new mattress topper over an existing mattress does not provide the fire protection that a new mattress provides.
Thus, a method is sought for upgrading an existing mattress and avoiding having to purchase an entirely new mattress, but yet obtaining the fire-protection benefits associated with a new mattress. In addition, a method is sought for avoiding the poor ventilation characteristics of a conventional memory-foam mattress topper.
SUMMARYThe following presents a simplified summary of some embodiments of the invention and is not intended to delineate the scope of the invention. This summary presents some embodiments in a simplified form as a prelude to the more detailed description that is presented below.
A mattress add-on with a flame-resistant covering is placed on top of an existing mattress and provides a rejuvenated fire-safe mattress. The flame-resistant covering of the mattress add-on has a skirt that fits tightly over the sides of the existing mattress. In addition, the flame-resistant covering has flaps that cover the bottom of the existing mattress.
By purchasing the mattress add-on with the flame-resistant covering, a consumer can rejuvenate his existing mattress and obtain many of the benefits of a more-expensive memory foam mattress. As an added benefit, the consumer obtains fire protection and renders his existing mattress flame resistant by enclosing all surfaces of the existing mattress inside the flame-resistant covering of the mattress add-on.
Comfort is improved and unsightly wrinkles are avoided by holding the mattress add-on tightly in place over the existing mattress. The mattress add-on does not slip on the existing mattress because it is held in place by tightening the flame-resistant covering using straps across the bottom of the existing mattress. In addition, the lower surface of the mattress add-on is made of slip-resistant fabric.
The mattress add-on may include metal coils or air chambers to conform to a user's physical profile. Holding the mattress add-on firmly in place is an added benefit where the mattress add-on is an air mattress or a spring mattress. The mattress add-on can also be customized to a user's physical profile by using zones of foam having different densities. For example, a zone with foam having one firmness may be arranged to accommodate the user's head and torso, while another zone with foam having a different firmness may be arranged to accommodate the user's legs.
Other embodiments and advantages are described in the detailed description below. This summary does not purport to define the invention. The invention is defined by the claims.
The accompanying drawings, where like numerals indicate like components, illustrate embodiments of the invention.
Reference will now be made in detail to some embodiments of the invention, examples of which are illustrated in the accompanying drawings.
Flame-resistant covering 12 also hangs down over the sides of existing mattress 11 and covers the bottom surface of existing mattress 11 as well. Flame-resistant covering 12 fits tightly over existing mattress 11 and holds mattress add-on 10 firmly in place. The lower surface 14 of mattress add-on 10 is prevented from slipping over the top surface 15 of existing mattress 11 by a rougher lower surface material of mattress add-on 10 and by the tension provided by flame-resistant covering 12.
Mattress add-on 10 may be configured in accordance with any number of shapes including, but not limited to: a rectangular shape, a square shape, an ovate shape, a circular shape, and a free-form shape without departing front the present invention. Still further, mattress add-on 10 configured in a rectangular shape may be configured in any number of sizes including, but not limited to: twin size, full size, queen size, king size, and California king size, without departing from the present invention.
Memory foam core layer 17 provides a second cushioning interface of mattress add-on 10 and is sized to conform to underlying layer 16. The memory foam of core layer 17 has a density selected for an individual user. For example, high density memory foam corresponding to a “hard” feel may be selected. Alternatively, low density memory foam corresponding to a “soft” feel may be selected. In addition, memory foam core layer 17 is configured to have a number of zones, each zone having a particular density. In the embodiment of
Topper layer 18 provides a fibrous padding layer for mattress add-on 10. As noted above, foam mattresses are typically produced from polymeric compounds. Sleeping on these polymeric compounds is not unlike sleeping on a plastic tarp. Users of foam mattresses may complain that their sleep is impaired due to excessive moisture accumulation as a result of sleeping on a non-breathable mattress. In some instances, a simple cover made of terry cloth or some other natural fiber weave may be implemented to address those concerns. However, a simple cover may still not provide sufficient breathability to achieve a comfortable sleep environment because the absorbing ability of a simple cover may not match a sleeper's expiration of water through sweat during a sleeping period. In addition, a simple cover may not sufficiently hold an underlying core layer in place. A foam mattress topper inside a simple cover may skew cover leaving uncomfortable and unsightly wrinkles. Thus, topper layer 18 contributes to the stability of mattress add-on 10.
Flame-resistant covering 12 tightly encases underlying layer 16, core layer 17 and a topper layer 18 and prevents the three layers from slipping over each other. The reduction in slippage adds to the user's comfort. Flame-resistant covering 12 may be made of one or more fabric materials. For example, flame-resistant covering 12 may be made of cotton, linen, wool, silk, nylon, an acrylic or other synthetic fabric that is impregnated with a fire retardant compound such as, but not limited to, boric acid (H3BO3), zinc borate, antimony trioxide (Sb2O3), vinylidene chloride, decabromodiphenyl oxide (DBDPO or Deca), Melamine or PVDC. Alternatively, flame-resistant covering 12 is made of a flame-retardant fabric such as, but not limited to, a fabric made of para-aramid fibers. In the embodiment of
In some embodiments, topper layer 18 comprises a fibrous woven padding. Materials selected for topper layers include natural fibers and synthetic fibers. Topper layer 18 also includes a fire retardant compound. By placing a fibrous layer over a foam core, a breathable layer is created, which may increase comfort for a user. Topper layer 18 also provides structural support for underlying memory foam core layer 17.
Flame-resistant covering 12 hangs down over the sides of existing mattress 11 and holds mattress add-on 10 firmly in place. An elastic band 19 around the bottom of flame-resistant covering 12 holds the sides of flame-resistant covering 12 tight around the four side surfaces of existing mattress 11. In addition, straps at the bottom of flame-resistant covering 12 also hold the covering tight. Finally, bottom flaps 20 and 21 of flame-resistant covering 12 cover all portions of the bottom surface of existing mattress 11 that are not covered by the skirt of flame-resistant covering 12.
Completely covering all six sides of existing mattress 11 with flame-resistant covering 12 renders the rejuvenated existing mattress flame-resistant. Federal regulations will soon require all new mattresses that are sold in the United States to pass an open-flame standard. For example, new flammability standards are prescribed for mattresses under 16 C.F.R. § 1633. A consumer who avoids the cost of a new mattress and simply places a new mattress topper over an existing mattress will not benefit from the new fire-protection safety regulations. Placing mattress add-on 10 over existing mattress 11 and covering all sides of the mattress add-on and existing mattress with flame-resistant covering 12 rejuvenates the existing mattress and creates a new open flame-resistant mattress combination. Because the bottom surface of existing mattress 11 is also covered by flame-resistant covering 12, an open flame on the outside of a fire-resistant covering on a side of flame-resistant covering 12 will not ignite the bottom of existing mattress 11 in an open-flame test performed pursuant to 16 C.F.R. § 1633. Thus, mattress add-on 10 in combination with flame-resistant covering 12 is an inexpensive means of providing both more comfort as well as fire protection safety to consumers who retain their existing mattresses.
A user may select a foam density for each zone that more accurately conforms to the user's physical profile. Zone 2 (53) may be composed of high density foam, while zone 1 (52) or 3 (54) may be composed of lower or higher density foam with respect to zone 2 (53). Zone 2 (53) may carry more weight from the torso of a user, thus requiring high density foam to achieve adequate cushioning. Zones 1 (52) and 3 (54) may carry less weight from head and legs, thus requiring lower density foam with respect to zone 2 (53). In another embodiment, zone 2 (53) may be configured with lower density foam with respect to zones 1 (52) and 3 (54). In yet another embodiment, foam density is approximately equivalent across zones 1 (52), 2 (53) and 3 (54).
Although certain specific exemplary embodiments are described above in order to illustrate the invention, the invention is not limited to the specific embodiments. For example, core layer 17, top layer 33 and middle layer 36 have been described as being foam layers having different densities in different zones. Different firmness in different sections of a mattress add-on can also be achieved, however, by using air bladders that are inflated to different pressures. In some embodiments, core layer 17, top layer 33 and middle layer 36 contain multiple air chambers, each having selectable air pressure that allow a user to customize his mattress add-on to accommodate his weight, height and sleep position. A higher air pressure in a section of the layer provides firmer support in that section. Where the mattress add-on includes air chambers, tightening flame-resistant covering 12 using the straps 22 holds the air mattress add-on firmly in place over existing mattress 11. Accordingly, various modifications, adaptations, and combinations of various features of the described embodiments can be practiced without departing from the scope of the invention as set forth in the claims.
Claims
1. A method comprising:
- placing a mattress add-on on a top surface of an existing mattress, wherein the existing mattress has a bottom surface, four side surfaces and the top surface, and wherein the mattress add-on has a flame-resistant covering; and
- covering the bottom surface and the four side surfaces of the existing mattress with the flame-resistant covering.
2. The method of claim 1, wherein the mattress add-on has a lower surface, further comprising:
- tightening the flame-resistant covering on the bottom surface of the existing mattress such that the lower surface of the mattress add-on does not slip on the top surface of the existing mattress.
3. The method of claim 2, wherein the tightening is performed using straps attached to the flame-resistant covering.
4. The method of claim 1, wherein the mattress add-on has two layers of foam.
5. The method of claim 4, wherein one of the layers of foam is made of memory foam.
6. The method of claim 1, wherein the mattress add-on includes metal coils.
7. An apparatus comprising:
- a mattress add-on, wherein the mattress add-on is adapted to lie on a top surface of an existing mattress, wherein the existing mattress has the top surface, a bottom surface and four side surfaces; and
- a flame-resistant covering attached to the mattress add-on, wherein the mattress add-on has an upper surface and four add-on side surfaces, and wherein the flame-resistant covering is adapted to cover the upper surface, the four add-on side surfaces, the four side surfaces of the existing mattress and the bottom surface of the existing mattress.
8. The apparatus of claim 7, further comprising:
- straps attached to the flame-resistant covering, wherein the straps are adapted to tighten the flame-resistant covering at the bottom surface of the existing mattress such that the flame-resistant covering holds the mattress add-on firmly to the existing mattress.
9. The apparatus of claim 7, wherein the flame-resistant covering includes bottom flaps, and wherein the bottom flaps are adapted to fold over the bottom surface of the existing mattress such that every portion of the bottom surface of the existing mattress is covered by the flame-resistant covering.
10. The apparatus of claim 7, wherein the mattress add-on includes metal coils.
11. The apparatus of claim 7, wherein each of the metal coils is made of a separate piece of metal.
12. The apparatus of claim 10, wherein each of the metal coils in enclosed in a separate fabric pocket.
13-14. (canceled)
15. The apparatus of claim 13, wherein the mattress add-on has two layers of foam.
16. An apparatus comprising:
- a mattress add-on, wherein the mattress add-on is adapted to lie on a top surface of an existing mattress, wherein the existing mattress has the top surface, a bottom surface and four side surfaces, wherein the mattress add-on includes metal coils; and
- a covering attached to the mattress add-on, wherein the mattress add-on has an upper surface and four add-on side surfaces, and wherein the covering is adapted to cover the upper surface, the four add-on side surfaces, the four side surfaces of the existing mattress and the bottom surface of the existing mattress.
17. The apparatus of claim 16, wherein each of the metal coils in enclosed in a separate fabric pocket.
18. The apparatus of claim 16, wherein the mattress add-on includes a layer of memory foam above the metal coils.
19. An apparatus comprising:
- an existing mattress;
- a mattress add-on that lies on a top surface of the existing mattress, wherein the existing mattress has a bottom surface, four side surfaces and the top surface; and
- means for rendering each of the top surface, the bottom surface and the four side surfaces of the existing mattress flame resistant, wherein the means covers the mattress add-on and the existing mattress.
20. The apparatus of claim 19, wherein the means is made of a fire-barrier fabric.
21. The apparatus of claim 19, wherein the existing mattress is not flame resistant.
22. The apparatus of claim 19, wherein the mattress add-on includes metal coils.
23. The apparatus of claim 19, wherein the mattress add-on includes a layer of memory foam.
Type: Application
Filed: Apr 24, 2007
Publication Date: Oct 30, 2008
Applicant:
Inventor: Youn Jae Lee (Pleasanton, CA)
Application Number: 11/789,256
International Classification: A47C 31/00 (20060101); A47C 27/00 (20060101); A47G 9/00 (20060101);