ENHANCED WASHABLE MATTRESS TOPPER

Abstract

An enhanced washable mattress topper is disclosed, which allows the entire topper (including the cushion element) to be washed and/or dried. The topper typically comprises a cushion element, which may include of a fiber-foam layer and a spacer fabric layer, within a cover. The cover is typically permanently attached to the cushion element, for example with stitching which may form a plurality of compartments by segmenting the cushion element

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority under 35 USC §119 to related and co-pending provisional patent application Ser. No. 62/232,994 entitled “Enhanced Washable Mattress Topper” filed Sep. 25, 2015 (with the year anniversary falling on a Sunday, so that this matter is timely filed to claim priority); and also claims priority benefit under 35 USC §120 to co-pending U.S. patent application Ser. No. 14/600,989 entitled “Washable Mattress Topper” tiled Jan. 20, 2015, which claims benefit under 35 USC §120 to U.S. patent application Ser. No. 13/624,525 (now U.S. Pat. No. 8,966,688) entitled “Washable Mattress Topper” filed Sep. 21, 2012, which claims priority under 35 USC §119 to U.S. Provisional Patent Application Ser. No. 61/537,986 filed on Sep. 22, 2011, entitled “Washable Mattress Topper” (such that this present application also claims priority to an effective filing date of Sep. 22, 2011 through U.S. Provisional Patent Application Ser. No. 61/537,986); all of which are hereby incorporated by reference as if reproduced in their entirety.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

REFERENCE TO A MICROFICHE APPENDIX

Not applicable.

BACKGROUND

A mattress topper is a cushioned item of removable bedding that typically sits on the top surface of a mattress. Mattress toppers may be used to promote increased comfort to a user while sleeping and may also protect a mattress hygienically and physically, such as from wear and tear imposed by use. Typically, a removable outer cover (and only the removable outer cover, for example not the actual cushioning element(s)) of a conventional mattress topper may be washed. regularly to maintain clean bedding. Applicant has developed a washable mattress topper, which may be repeatedly washed and dried as a whole (e.g. in its entirety, for example more than just the cover, including for example the cushioning element) without significantly damaging the cushioning element of the topper. These and other improvements are discussed below in more detail.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the present disclosure, reference is now made to the following brief description, taken in connection with the accompanying drawings and detailed description, wherein like reference numerals represent like parts.

FIG. 1 illustrates an exemplary enhanced washable mattress topper embodiment in perspective view with a cut-away view of the cover (to show the cushion element within the cover), and illustrates a quilting pattern with a border compartment and a plurality of square or rectangular central compartments;

FIG. 2A illustrates a cross-section view of a portion of a mattress topper embodiment with an uncompressed cushion element;

FIG. 2B illustrates a cross-sectional view of a portion of a mattress topper embodiment with a compressed cushion element and an attachment (for example, via stitching) of the cover surfaces to the cushion element (for example, with stitching passing through the upper surface of the cover, the cushion element, and the lower surface of the cover, with such stitching typically compartmentalizing the cushion element);

FIG. 3 illustrates a perspective view of another mattress topper embodiment with a cut-away view of the cover (to show the cushion element within the cover), and illustrates a quilting pattern with a border compartment and a plurality of central compartments formed by one or more helical patterns;

FIG. 4. illustrates a perspective view of another mattress topper embodiment with a cut-away view of the cover (to show the cushion element within the cover and illustrates a quilting pattern formed by crisscrossed diagonal stitching lines (which might for example form a plurality of polygon shaped compartments);

FIG. 5 illustrates a perspective view of another mattress topper embodiment with a en away view of the cover (to show the cushion element within the cover), and illustrates a quilting pattern with a border compartment and a plurality of central triangular compartments;

FIG. 6 illustrates a perspective view of another mattress topper embodiment with a cut-away view of the cover (to show the cushion element within the cover), and illustrates a quilting pattern formed by a plurality of typically continuous stitching lines spanning the width of the topper (for example, forming rectangular compartments across the width of the topper);

FIG. 7 illustrates a perspective view of another mattress topper embodiment with a cut-away view of the cover (to show the cushion element within the cover), and illustrates a quilting pattern formed by a plurality of typically continuous stitching lines spanning the length of the topper (for example, forming rectangular compartments across the length of the topper);

FIG. 8 illustrates a perspective view of another mattress topper embodiment with a cut-away view of the cover (to show the cushion element within the cover), and illustrates a quilting pattern with a border compartment;

FIG. 9 illustrates a cut-away perspective view of an exemplary enhanced washable mattress topper embodiment (of the sort shown in FIGS. 1-8 for example), showing the internal components (such as the cushion element comprising fiber-foam and spacer fabric) of the topper;

FIG. 10 illustrates a cut-away perspective view of another mattress topper embodiment (of the sort shown in FIGS. 1-8 for example), showing the internal components (such as the cushion element comprising fiber-foam and spacer fabric and non-slip material) of the topper;

FIG. 11 illustrates a cut-away perspective view of another exemplary enhanced washable mattress topper embodiment (of the sort shown in FIGS. 1-8 for example), showing the internal components (such as the cushion element comprising a fiber-foam layer and two spacer fabric layers sandwiching the fiber-foam) of the topper; and

FIG. 12 illustrates in exploded view the components of the exemplary topper embodiment of FIG. 9.

DETAILED DESCRIPTION

It should be understood at the outset that although illustrative implementations of one or more embodiments are illustrated below, the disclosed systems and methods may be implemented using any number of techniques, whether currently known or not yet in existence. The disclosure should in no way be limited to the illustrative implementations, drawings, and techniques illustrated below, but may be modified within the scope of the appended claims along with their full scope of equivalents.

The following brief definition of terms shall apply throughout the application:

The term “comprising” means including but not limited to, and should be interpreted in the manner it is typically used in the patent context;

Directions, such as up (e.g. upward) and/or down (e.g. downward), typically are intended to be based on the mattress (or sleep system or foundation) in its normal sleeping position as understood by persons of skill; for example, the upper surface of the mattress might face towards the ceiling and/or serve as the sleep surface upon which the user might lie, while the bottom surface of the mattress might face towards the floor or ground and/or be placed atop a foundation element;

The phrases “in one embodiment,” “according to one embodiment,” and the like generally mean that the particular feature, structure, or characteristic following the phrase may be included in at least one embodiment of the present invention, and may be included in more than one embodiment of the present invention (importantly, such phrases do not necessarily refer to the same embodiment);

If the specification describes something as “exemplary” or an “example,” it should be understood that refers to a non-exclusive example;

The terms “about” or approximately” or the like, when used with a number, may mean that specific number, or alternatively, a range in proximity to the specific number, as understood by persons of skill in the art field (for example, +/−10%); and

If the specification states a component or feature “may,” “can,” “could,” “should,” “would,” “preferably,” “possibly,” “typically,” “optionally,” “for example,” “often,” or “might” (or other such language) be included or have a characteristic, that particular component or feature is not required to be included or to have the characteristic. Such component or feature may be optionally included in some embodiments, or it may be excluded.

Embodiments relate generally to mattress toppers (or other cushioned support devices) which may be made washable as a whole (for example, allowing multiple washing and drying cycles, for example in typical washer and drier units, without significant degradation to the cushioning element(s) of the topper). Disclosed embodiments provide an improvement/enhancement to an earlier washable mattress topper developed by the Applicant, namely the washable topper set forth in U.S. Pat. No. 8,966,688 (hereby fully incorporated by reference to the extent it does not directly contradict the immediate disclosure herein), which used compartmentalization of the cushion element (which typically comprised an open cell foam material) of the topper (or device). Typically, such compartmentalization was accomplished by quilting techniques, with stitching passing through the ticking forming the upper and lower surface of the outer cover of the topper, as well as the open cell foam cushion element. While embodiments of the present improvement/enhancement often may include compartmentalization similar to that described in U.S. Pat. No. 8,966,688, they also typically comprise different cushioning/support materials/elements (instead of (or in some embodiments, in addition to) the open cell foam described in the earlier patent, for example). Consequently, the disclosed embodiments herein may provide even further improvement in washability and/or may be lighter in weight and/or thickness (which may improve machine washability) while still providing effective cushioning/support (for example comparable to the earlier washable topper discussed above). These enhanced topper embodiments will be described in more detail below.

While the embodiments described below may discuss mattress toppers, it should be understood that use of the term “mattress topper” or “topper” herein is merely exemplary and may not be limiting, and that embodiments may also relate to other cushioned support devices (such as pillows, mattresses (or elements within a mattress), for example). Furthermore, while the enhanced washable mattress topper examples herein may generally be discussed in the sleeping context or for use on the top surface of a mattress, enhanced washable cushioned support devices (with similar features) may have other uses (for example, seating cushions or lumbar support cushions), all of which are within the scope of this disclosure.

Mattress toppers generally are designed for the purpose of increased comfort while sleeping and to protect mattresses hygienically and/or from wear and tear. It is typically not common practice to wash an entire conventional topper because it may cause deterioration (and typically significant deterioration of the cushioning element of the topper. However, a washable mattress topper (for example, allowing the entire topper to be washed, including the cushioning element(s) as a whole and/or all together at one time) may be desired to allow for more hygienically clean bedding. So, it may be desirable that a mattress topper be machine or hand washable for hygienic reasons, including the elimination of dirt, allergens and other irritants (e.g. dust mites, bed bugs, mold and dead skin).

The cushioning element(s) (e.g. the cushioning/support material located between the cover/ticking) of disclosed embodiments may comprise a fiber-foam layer and/or a spacer fabric layer (and typically would comprise both fiber-foam and spacer fabric, for example, instead of typical open and/or closed cell foam). For example, spacer fabric might be laminated to at least one surface of the fiber-foam layer, to form a cushioning element for the enhanced washable mattress topper (and in some embodiments, spacer fabric might be laminated to both the upper and lower surface of the fiber-foam layer). So for example, an exemplary enhanced washable mattress topper might comprise a fiber-foam layer, a spacer fabric layer, and a ticking or cover which encompasses both the fiber-foam layer and the spacer fabric layer to form the exterior of the topper (for example, with an upper/sleep support surface and a bottom surface configured to lay atop the mattress).

Some disclosed embodiments may comprise the attachment of a fabric cover (e.g. ticking) to the cushion element of a mattress topper in a manner that creates a plurality of compartments within the cushion element, wherein the fabric cover permanently encloses the cushion element. In this disclosure, “permanently enclose” means that it may be possible to remove the fabric cover by laboriously cutting or otherwise removing the attachment between the cover and the cushion element (which may he stitches, for example), but this removal may effectively destroy or ruin the mattress topper. At the least, it would be very inconvenient to remove the fabric cover, and removal would defeat at least one of the benefits of the invention, including the ability to wash the topper without having to remove and later reinsert the cushion element. In the language of this disclosure, “permanently” means that the fabric cover remains in enclosure of the cushion element for the duration of the functional life of the disclosed mattress toppers. So for example, the compartments might be formed by quilting/stitching the cover to the one or more cushioning elements, for example with stitching passing through the upper cover/ticking layer/surface, the one or more cushioning elements, and the bottom/lower cover/ticking layer/surface. While the creation of a plurality of compartments within the cushion element (e.g. the fiber-foam layer and the spacer fabric layer) by attachment of the cover is typically used in such disclosed embodiments (to improve washability), some embodiments may not require such compartmentalization (for example, relying on the use/selection of fiber-foam and spacer fabric for the cushion element to provide the desired washability).

So, disclosed embodiments typically would comprise a spacer fabric layer and a fiber-foam layer (which jointly form the cushioning element of the topper), along with a cover/ticking which encompasses the cushioning element (i.e. the spacer fabric and fiber-foam). Typically, the spacer fabric would be laminated to the fiber-foam layer, to jointly form the cushioning element of the topper (although in other embodiments, the spacer fabric and the fiber foam layer might only be joined by the stitching of the quilting pattern for attachment of the cover). And typically, the cover/ticking would be quilted/stitched onto the cushioning element (e.g. spacer fabric and fiber-foam layer), permanently joining the cover to the cushioning layer. In most disclosed embodiments, the quilting approach would have stitching (which passes through both the upper and lower layers/surfaces of the cover and the fiber-foam layer and the spacer fabric) which divides or segments the cushioning element into a plurality of compartments.

Some embodiments might comprise two spacer fabric layers, with an upper spacer fabric laminated atop (and in direct contact with) the fiber-foam layer, and a lower spacer fabric layer laminated beneath (and in direct contact with) the fiber-foam layer (such that the cushioning element might be formed of the fiber-foam layer and two spacer fabric layers). Most often, if there are two spacer fabric layers, these spacer fabric layers would be identical (in material, thickness, etc.), although in other embodiments the upper spacer fabric layer and the lower spacer fabric layer could be different (for example, formed of different material, have different dimensions, and/or have different properties). Some embodiments might also optionally comprise a non-slip (for example PVC) layer (which could be the lower cover surface/layer in some embodiments or could be a separate layer located beneath the cushioning element and between the cushioning element and the lower cover layer in other embodiments).

Typically, the fiber-foam layer would comprise fibers distributed approximately evenly throughout the foam material, and typically, the ratio of fibers to foam would be approximately a level providing effective support/comfort characteristics. In some embodiments, the fiber-foam material might comprise polyurethane (for example, open cell in some embodiments) foam and polyurethane fibers.

Typically, the spacer fabric layer(s) would be formed of spacer fabric, for example a 3D warp knit fabric product, which might be knitted in a lofted manner (for example, with a middle layer of monofilament yarn sandwiched between and connecting two outer surface layers of fabric). Typically, the outer layers of fabric forming the spacer fabric would be an open mesh fabric material, such that the spacer fabric might comprise an upper surface of mesh fabric, a lower surface of mesh fabric, and a 3D spacer microfilament yarn layer knit between and connecting the upper and lower mesh fabric surfaces. Typically, the ratio of spacer fabric layer thickness to fiber-foam layer thickness in the cushion element might be approximately 1:1 or 1:1.5 (for example, ith the spacer fabric layer perhaps having an uncompressed thickness of about 1-1.5 cm (for example approximately 1 cm) while the fiber-foam layer might have a thickness of about 1-1.5 cm, 1-2 cm, or 1.5-2 cm (for example, approximately 1.5 cm)). And typically, the airflow rate of the spacer fabric layer might be sufficient to allow for effective drying.

Typically, the ticking/cover would be fabric and typically would be permanently attached to the cushion element, for example by stitching (which might form a quilting pattern, for example, forming a plurality of compartments segmenting the cushion element). So for example, the ticking/cover might comprise an upper surface layer and a lower surface layer, with the cushion element located between (and typically in contact with) the upper surface layer and the lower surface layer of the cover, and stitching (for example, forming a quilting pattern resulting in a plurality of compartments) might pass through the upper surface layer of the cover, through the cushion element (for example through both the fiber-foam layer and the one or more spacer fabric layers), and through the lower surface layer of the cover (e.g. joining both the upper and lower surface of the cover to the cushion element, as well as further joining (and often compressing and locking in (e.g. securely fixing) the compression) the spacer fabric to the fiber-foam). So for example, the thickness of the cushion element at the stitching might typically be the thickness at which the cushion element is compressed (for example, to about its maximum compression).

In some embodiments, more than one type of stitching might be used to form the quilting (e.g. permanently attach the cover to the cushion element). So for example, a combination of tack-and-jump stitching and channel stitching might be used, for example with the channel stitching connecting points tacked by the tack-and-jump stitching. Furthermore, the channel stitching might comprise 4-8 stitches per inch (for example, perhaps 6 stitches per inch). The stitching might form a plurality of compartments dividing the cushion element, such that all of the plurality of compartments might have approximately the same thickness of cushioning (resulting from being formed by division of the same unified cushion element by stitching). And often, several (and sometimes all) of the plurality of compartments might be equally shaped and sized (e.g. identical). In sonic embodiments, several of the compartments might be rectangular, triangular, or helical in shape. In some embodiments, there may be a border compartment about the perimeter of the topper, with a plurality of central compartments located within the border compartment. In such instances, the central compartments typically would be equally sized and/or shaped.

The illustrative examples shown in the figures and described below may provide more detailed examples of the disclosed enhanced washable mattress topper embodiments.

FIG. 1 illustrates an exemplary embodiment of an enhanced washable mattress topper. In the embodiment shown in FIG. 1, a mattress topper 100 may consist of a cushion element 102 with a fabric cover 104 enclosing and attached to the cushion element 102 in a manner that creates multiple central compartments 106 and a border compartment 108. In an embodiment, the cushion element 102 may comprise a fiber-foam layer and at least one spacer fabric layer (as will be discussed in more detail below). The fabric cover 104 may comprise natural materials (such as cotton, linen, wool, silk, or bamboo, for example), synthetic materials (such as polyester, rayon, Dacron, nylon, acrylic, Lycra, or olefin fibre, for example), or a combination (or blend) thereof. Any combination and/or construction of natural materials and/or synthetic materials may be suitable for the fabric cover 104, and the cover 104 may be configured so as to resist significant shrinking and/or stretching of the fabric when washed and/or dried. This may be accomplished by preshrinking the fabric cover material, using a specific type of weave for the material, and/or using specific material(s) for the fabric cover that are known to be stable. Additionally, the cover 104 typically would be sufficiently porous so that water can effectively drain through the cover and/or so that airflow may be sufficient to improve drying. Typically, the fabric cover 104 may comprise a woven material.

In an embodiment, the fabric cover 104 may be attached to the cushion element 102 by stitching with thread 110 and 112 through both the fabric cover 104 (for example, both the top surface 1.20 and the bottom surface 130 of the cover) and the cushion element 102. In an embodiment, stitching continuous lines with thread may achieve compartmentalization of the mattress topper 100. “Continuous” may refer to stitching without breaking/cutting the thread at any point in a particular line/distance. Although, in an embodiment, the thread may be visible on one side of the fabric cover 108 in a dashed fashion (such that the stitching alternates between two surfaces 120 and 130 of the fabric cover 104), it may be considered a continuous stitch if the thread used to make the stitch is not broken and/or cut along a specific line. In an embodiment, a stitching pattern on a topper 100 (such as may be formed by stitching 110 and 112) may be formed by one or more continuous lines of stitching. For example, in FIG. 1 one continuous line of stitching 112 might form a border compartment 108, while a plurality of horizontal lines of continuous stitching and a plurality of vertical lines of continuous stitching might form a plurality of central compartments. The stitching 110 and 112 may be applied through both the fabric cover 104 and the cushion element 102 (i.e. between the top 120 and bottom 130 surfaces of the fabric cover 104) so that, in an embodiment, the distance between the top 120 and bottom 130 of the mattress topper 100 at the stitching 110 and 112 may be between about ⅛ inch and about ¾ inch (or in other embodiments perhaps between 1/16 inch and ½ inch (while the uncompressed thickness of the cushion element/mattress topper away from the stitching might typically be about 1-2.5 inches or 1-1.5 inches). Generally, the thickness of the cushion element 102 at the stitching 110 and 112 may be a thickness at which the cushion element 102 is compressed, wherein the cushion element 102 may be approximately fully compressed or partially compressed, as can be seen in FIGS. 2A-2B. Additionally, the compression at the stitching 110 and 112 may be accomplished by applying a specific force to the cushion element 102.

FIG. 2A shows a cushion element 202 in an uncompressed state. In an embodiment, the top surface 220 and the bottom surface 230 of the fabric cover 204 may each be adjacent to the cushion element 202 (for example, on opposite sides). FIG. 2B shows the cushion element 202 at a point of attachment 211 with the fabric cover 204. The cushion element 202 may be in a compressed state at the attachment point 211, and, as can be seen in FIG. 2B, the attachment 211 may attach the top 220 and bottom 230 surfaces of the fabric cover 204 to the cushion element 202 by threading all the way through the cushion element 202, thereby creating two compartments 250 and 251 of the cushion element 202 on either side of the attachment point 211. As can be seen from FIG. 2B, the cushion element 202 may have a compressed thickness at the attachment point 211, and it may be substantially less than the uncompressed thickness of the cushion element 202.

While one embodiment of compartmentalization of the mattress topper may be achieved by stitching continuous lines with thread (for example, forming a quilting pattern), other methods are equally contemplated, such as stitching without continuous lines, fusing, use of adhesive, use of rivets, use of buttons or some combination thereof. Additionally, an embodiment of the mattress topper shown in FIG. 1 may comprise a connection 125 of the top 120 and bottom 130 surfaces of the fabric cover 104 (for example, to form a sealed envelope capable of completely enveloping the cushion element on all sides), wherein the connection may comprise stitching and may be located at the edges of the topper 100. The top and bottom surfaces may be connected on at least one edge, and may also comprise two separate pieces connected at all four edges. So for example, typically the cover might be formed with three closed sides (for example a top, bottom, and three sides, which might be pre-sewn from multiple pieces of fabric, for example) and one open side, and the open side would then be sealed or closed (for example, by stitching connection 125) only after insertion of the cushion element.

In an embodiment, the stitching 110 and 112, operable to attach the cushion element and fabric cover, may be in a pattern such that the number of stitches per inch may be between about 4 and about 8, and in some embodiments, may comprise between approximately 5 to 7 stitches per inch. In a typical embodiment, the stitching pattern 110 and 112 may comprise approximately 6 stitches per inch. In an embodiment, the thread used for the stitching may comprise Nylon and may have a thread weight of at least approximately Tex 6 (wherein Tex is the mass in grams of 1000 meters of thread). In other embodiments, the thread may comprise other materials such as cotton, polyester, a cotton-polyester blend, rayon, silk, or wool, which may be chosen based on the desired qualities of the thread such as strength, thickness, appearance, stability during washing and/or drying, and/or cost. In an embodiment, the stitching 110 and 112 may be completed using one or more quilting/stitching methods, which may include channel stitching and/or tack-and-jump. In an embodiment, the fabric cover 104 and cushion element 102 may first be tacked together (i.e. tacked with thread from one surface of the fabric cover to the other surface through the cushion element) in a plurality of points on the topper 100 (which may be located within the stitching pattern 110 and 112) using a tack-and-jump method. Then, channel stitching may be used to form the final pattern of stitching 110 and 112 on the topper 100 that may ultimately create the plurality of compartments 106 and 108 in the topper 100. In an embodiment, the channel stitching may connect the plurality of points that may be tacked by the tack-and-jump method. The embodiment of attaching the fabric cover 104 and cushion element 102 combining the use of tack-and-jump and channel stitching may allow for increased stability of the cushion element 102 in the stitching pattern. In an embodiment, the tack-and-jump followed by channel stitching may firmly fix the cushion element 102 within the pattern of compartmentalization, such that during washing and/or drying, the cushion element 102 and/or the fabric cover 104 may not develop puckers or deformities at or around the stitching 110 and 112.

The size and/or shape of the compartments may affect the comfort of the topper 100 for a user as well as manufacturing costs associated with the topper 100. In the embodiment shown in FIG. 1, the central compartments 106 separated by stitching 110 may comprise a rectangular shape. Additionally, the rectangular central compartments 106 may be approximately uniform wherein the ratio of the length to the width of the central compartments 106 may be between about 0.4 and 2.5. In another embodiment, the ratio of the length to the width of the central compartments 106 may be between about 0.5 and 2.0, such that the longer side is no more than twice the length of the shorter side. In an embodiment wherein the longer side is no more than twice the length of the shorter side, elongation of an area of the cushion element (which may cause deformation or alteration of the rigidness and/or comfort properties of the cushion element when washed) may be avoided. In yet another embodiment, the ratio of the length to the width of the central compartments 106 may be between about 0.8 and 1.25, such that the central compartments 106 have an approximately square shape. In an embodiment, the length and width of the compartments may be between about 5 inches and about 15 inches. In a typical embodiment, the central compartments 106 may be about 8 inches in length and about 8 inches in width. Uniformity provided by regularly shaped compartments 106 (such as a square or triangle, for example) may provide stability to the cushion element 102 (to prevent deterioration for example) during washing and/or drying to allow for a longer lifespan of the topper 100. Thus, typically the central compartments may all be sized and shaped uniformly/identically. In an embodiment, the border compartment 108 may be operable to provide stability to the topper 100, especially at the outer edges. In the embodiment shown in FIG. 1, the border compartment 108 may completely surround the central compartments 106, wherein the border compartment may be separated from the central compartments by stitching 112. The border compartment 108 may typically be continuous around the outside edge of the topper 100, as shown in FIG. 1, and may, in an embodiment, have a width of between about 3 inches and about 6 inches. In an embodiment, the border compartment 108 may comprise a width between about 2 inches and about 4 inches, while in another embodiment, the border compartment may comprise a width of less than 3 inches. In a typical embodiment, the width of the border compartment may be approximately 3 inches.

In an embodiment, a topper 100 without a border compartment 108 may develop irregularity in deformation or decomposition at the edges of the topper caused by washing and/or drying of the topper. Typically, a topper without a border compartment may have a lifespan of about 25 to 30 washes, whereas a topper with a border compartment may have a lifespan of at least 40 washes or more (which may be the equivalent of 20 years with 2 washings a year). The border compartment 108 may create strength for the cushion element 102, at the outer edges, especially at the corners, and serve to reinforce them during washing and/or drying. Additionally, the border compartment 108 may reinforce the stability of the topper 100 during regular use of the topper 100, such as when a user moves onto or off of the topper 100 or to a different position on the topper 100.

While many embodiments may comprise both a border compartment and a plurality of central compartments, other embodiments may comprise either just a border compartment alone (e.g. surrounding just one large central compartment) or just a plurality of central compartments alone (e.g. a plurality of compartments spanning the enter portion of the topper without an enclosing border compartment located about the edges of the topper upper surface). Persons of skill will understand the various combinations of compartments, several of which will be illustrated in more detail below with respect to specific figures. It may even be possible in some embodiments to have a washable topper without such compartments (for example, due to the nature of the cushion element with fiber-foam and spacer fabric), although typically even disclosed toppers with fiber-foam and spacer fabric would comprise at least one compartment (formed by quilting, for example), as discussed above.

In an embodiment, the cushion element 102 may comprise an uncompressed thickness up to approximately 2.5 inches. An embodiment of the cushion element 102 may have an uncompressed thickness of at least 1 inch, ranging from 1-1.5 inches, and/or may typically be about 1.5 inches thick. Different factors that may be considered to determine an optimal thickness of a topper 100 may include user comfort, ability to be washed and/or dried, and/or ability to be sewn through with stitching to create compartments. In an embodiment, the thickness of the cushion element 102 may be such that it allows for a user to handle (i.e. move, wash, and/or dry) the topper 100 with relative ease while still retaining comfort properties of the topper 100. A desired thickness may also depend on the density of the topper 100, wherein a typical embodiment of the cushion element 102 may comprise a density of about 3 lb. per board foot (wherein 1 lb. per board foot may be the equivalent of 12 lb. per cubic foot), or in some embodiment a density of less than 3 lb. per board foot. Because a typical mattress topper 100 may spend the majority of its lifespan on the top surface of a mattress, the topper 100 may not be made to be easily rolled or folded for storage; therefore the thickness of the topper may not need to be designed with folding or rolling characteristics.

FIGS. 3-8 show alternative embodiments of quilting patterns for attachment (of the cover to the cushion element) to create compartmentalization. While FIGS. 3-8 have been provided for exemplary purposes, other (quilting) patterns of compartmentalization may be included in the scope of this disclosure.

Shown in FIG. 3, an embodiment of a mattress topper 300 is briefly described. The mattress topper 300 comprises a cushion element 302, a fabric cover 304, and a border compartment 308 substantially as described above with reference to the cushion element 102, fabric cover 104, and border compartment 108 of FIG. 1. In the embodiment of FIG. 3, the mattress topper 300 may comprise a different pattern of stitching 310 and 312 that may provide a plurality of central compartments with various shapes and sizes 320a, 320b and 320c. In an embodiment, the stitching 312 may form the border compartment 308 and the stitching 310 may form the various shapes of central compartments 320a, 320b and 320c. In the embodiment of FIG. 3, the stitching 310 may be in a helical pattern in a horizontal and/or vertical (or other, such as diagonal) direction across the topper 300. The term “helical” may refer to continuously stitched lines that may be interwoven or interlocking, and may approximately comprise the shape of two sine waves (one inverse of the other) which may cross at multiple locations along their length. An exemplary helical pattern shown in FIG. 3 may comprise at least two continuous stitches 330 and 335 which may cross each other multiple times (in an interwoven fashion) and may form three differently shaped central compartments 320a, 320b and 320c, wherein compartment 320a may be formed between the two helical stitches 330 and 335, compartment 320b may be formed between a first side of the helical stitches 330 and 335 and the stitches 312 forming the border compartment 308, and compartment 320c may be formed between a second side of the helical stitches 330 and 335 and a first side of another set of helical stitches. In an embodiment, the topper 300 may comprise any number of helical patterned stitches 310, which may follow any direction with respect to the topper 300, so long as the thickness of the cushion element 302 (for comfort and support) is not compromised. Additionally, design may be considered for the stitching pattern, and the exemplary pattern in a helical shape may be considered aesthetically pleasing to a user.

Shown in FIG. 4, another embodiment of a mattress topper 400 is briefly described. The mattress topper 400 may comprise a cushion element 402 and a fabric cover 404 substantially as described above with reference to the cushion element 102 and fabric cover 104 of FIG. 1. In the embodiment of FIG. 4, mattress topper 400 may comprise a different pattern of stitching 410 which provides a plurality of polygon shaped compartments 406. In the embodiment of FIG. 4, the stitching 410 may continue to the edge of the mattress topper 400 (e.g. there may be no border compartment, although in other embodiments such quilting pattern could be used within a border compartment), and the compartments 406 may comprise a uniform, rectangular shape. In the embodiment of FIG. 4, the stitches 410 may follow a diagonal direction with respect to the mattress topper 400 (e.g. with crisscrossing diagonal stitching lines forming the polygon shaped compartments 406), but in other embodiments, the one or more of the stitching lines might be vertical and/or horizontal. Additionally, the embodiment of FIG. 4 may show rectangular shaped central compartments 406, but in other embodiments, the compartments may have more or less than four sides and may comprise right angles, obtuse angles, and/or acute angles.

Shown in FIG. 5, another embodiment of a mattress topper 500 is briefly described. The mattress topper 500 may comprise a cushion element 502, a fabric cover 504 and a border compartment 508 substantially as described above with reference to the cushion element 102, fabric cover 104, and border compartment 108 of FIG. 1. In the embodiment of FIG. 5, the mattress topper 500 may comprise a pattern of stitching 510, 511 and 512 which may provide a plurality of triangular central compartments 506. In the embodiment shown in FIG. 5, the stitching 511 may follow a diagonal direction with respect to the topper and the stitching 510 may follow a vertical and/or horizontal direction with respect to the topper, thereby forming the triangular central compartments 506. In another exemplary embodiment, the topper 500 may comprise additional stitching 515 which may alter the size and or shape of the central compartments 506.

Shown in FIG. 6 is another exemplary embodiment of a mattress topper 600 illustrating yet another quilting/stitching pattern. The mattress topper 600 may comprise a cushion element 602 and a fabric cover 604 substantially as described above with reference to the cushion element 102 and fabric cover 104 of FIG. 1. In the embodiment of FIG. 6, the mattress topper 600 may comprise a pattern of stitching 610 which may provide a plurality of rectangular compartments extending across the width of the mattress topper 600 (typically without a border compartment). In other words, the stitching 610 may form lines across the width of the topper 600, extending substantially from one side to the other side across the width of the topper 600 (although in some embodiments, the stitching may not extend all the way to the edge of the upper surface of the topper, but might provide a slight gap at the edges while extending across the central portion of the topper). So in some embodiments, a plurality of continuous stitching lines might extend horizontally across substantially the width of the topper 600 (for example, with no border compartment encompassing the central compartments 607). In other embodiments, not shown, the central compartments 607 (formed by a plurality of horizontal stitching lines as discussed above) might be encompassed by a border compartment located about the edges of the upper surface of the topper (as described above with respect to FIG. 1, for example). Typically, such rectangular central compartments 607 extending substantially the width of the topper 600 might have a width of about 5-10 inches (for example approximately 9 inches) (e.g. with the horizontal stitching lines located about 5-10 inches apart (for example approximately 9 inches apart)), while extending substantially across the width of the topper 600, for example.

Shown in FIG. 7 is another exemplary embodiment of a mattress topper 700 illustrating yet another quilting/stitching pattern. The mattress topper 700 may comprise a cushion element 702 and a fabric cover 704 substantially as described above with reference to the cushion element 102 and fabric cover 104 of FIG. 1. In the embodiment of FIG. 7, the mattress topper 700 may comprise a pattern of stitching 710 which may provide a plurality of rectangular compartments extending across the length of the mattress topper 700 (typically without a border compartment). In other words, the stitching 710 may form lines across the length of the topper 700, extending substantially from one side (e.g. foot) to the other side (e.g. head) across the length of the topper 700 (although in sonic embodiments, the stitching may not extend all the way to the edge of the upper surface of the topper, but might provide a slight gap at the edges while extending across the central portion of the topper). So in some embodiments, a plurality of continuous stitching lines might extend vertically across substantially the length of the topper 700 (with no border compartment encompassing the central compartments 707). In other embodiments, not shown, the central compartments 707 (formed by a plurality of vertical stitching lines as discussed above) might be encompassed by a border compartment located about the edges of the upper surface of the topper (as described above with respect to FIG. 1, for example). Typically, such rectangular central compartments 707 extending substantially the length of the topper 700 might have a width of about 5-10 inches (for example approximately 9 inches) (e.g. with the vertical stitching lines located about 5-10 inches apart, for example approximately 9 inches apart), while extending substantially across the length of the topper 700, for example.

Shown in FIG. 8 is another exemplary embodiment of a mattress topper 800 illustrating yet another quilting/stitching pattern. The mattress topper 800 may comprise a cushion element 802, a fabric cover 804, and a border compartment 808 substantially as described above with reference to the cushion element 102, fabric cover 104, and border compartment 108 of FIG. 1. In the embodiment of FIG. 8, the mattress topper 800 may comprise only a single central compartment 807 located within the border compartment 808 (e.g. the stitching which forms the border compartment might also form the single central compartment). Of course, in other embodiments, there may be a plurality of central compartments within the border compartment, for example formed by additional stitching (similar to examples discussed above).

As can be seen from the embodiments shown in FIGS. 1-8, any combination of vertical, horizontal, diagonal and/or curved stitches (which may be any number and/or length) may be used to form the central and/or border compartments of the topper and may be included in the scope of this disclosure. However, constraints may be placed on the size of the compartments to preserve the integrity and/or thickness of the cushion element of the topper. In other words, the compartments (including central and border compartments) may be small enough and/or close enough together to moderate or attenuate disintegration of the cushion element during a washing and/or drying process, while not being so small and/or close together as to compromise the integrity/thickness (and therefore the comfort/support properties) of the cushion element. Additionally, the complexity of the stitching pattern and/or the amount of thread used may be limited by manufacturing costs of the topper.

FIGS. 9-11 show cut-away views of exemplary toppers (which might be similar to those discussed above, for example with respect to the compartments/quilting pattern), illustrating in more detail the internal components of such exemplary toppers (which typically are similar except in the aspects explicitly discussed). For example, the exemplary toppers of FIGS. 9-11 may comprise a cushion element (located within a cover/ticking) including a fiber-foam layer and at least one spacer fabric layer. FIG. 12 shows an exploded view of the embodiment of FIG. 9, further detailing the internal elements. Thus, FIGS. 9-12 may help to further illustrate the cushion element embodiments discussed above.

FIG. 9 illustrates a (cut-away) portion of an exemplary topper 900 (which might be similar to any of the toppers from FIGS. 1-8, for example). As the cut-away view shows, the topper comprises a cover/ticking 904 (with an upper surface and a lower surface (and side surfaces)) which encompasses a cushion element 902. The cushion element 902 in FIG. 9 comprises a fiber-foam layer 902a and a spacer fabric layer 902b, with the spacer fabric layer 902b directly contacting one surface of the fiber-foam layer 902a. For example, the spacer fabric layer 902b might underlie the fiber-foam layer 902a. And in some embodiments, the spacer fabric layer 902b may be attached to the fiber-foam layer 902a. Typically, such attachment of the spacer fabric layer 902b to the fiber-foam layer 902a might be by stitching (for example, the stitching that forms the compartments discussed above) and/or lamination (for example adhesive binding the spacer fabric layer to the fiber-foam layer). In some embodiments, such as shown in exemplary FIG. 10 (which is similar in many ways to FIG. 9), the cushion element 1002 might also comprise a non-slip layer 1005 (for example of PVC), in addition to the fiber-foam layer 1002a and the spacer fabric layer 1002b (which are similar to those described above with respect to FIG. 9). And again (similar to FIG. 9), the cover encompasses/envelops the cushion element 1002.

FIG. 11 illustrates a (cut-away) portion of another exemplary topper 1100 (which might be similar to any of the toppers from FIGS. 1-8, for example), which is similar to that shown in FIG. 9 but which has a cushion element 1102 which comprises two spacer fabric layers 1102b, c on either side of the fiber-foam layer 1102a. As the cut-away view shows, the topper comprises a cover/ticking 1104 (with an upper surface and a lower surface (and side surfaces)) which encompasses a cushion element 1102. The cushion element 1102 in FIG. 11 comprises a fiber-foam layer 1102a, an upper spacer fabric layer 1102b, and a lower spacer fabric layer 1102c, with the spacer fabric layers 1102b,c directly contacting opposing surfaces of the fiber-foam layer 1102a. For example, one spacer fabric layer 1102c might underlie the fiber-foam layer 1102a, while the other spacer fabric layer 1102b might lie atop fiber-foam layer 1102a. And in some embodiments, the spacer fabric layers 1102b,c may be attached (for example, permanently attached) to the fiber-foam layer 1102a. Typically, such attachment of the spacer fabric layer 1102b, c to the fiber-foam layer 1102a might be by stitching (for example, the stitching that forms the compartments discussed above) and/or lamination (for example adhesive binding the spacer fabric layer to the fiber-foam layer).

FIG. 12 illustrates an exploded view of an exemplary mattress topper 1200 which is similar to the topper of FIG. 9, showing the relationship of the various components of the topper (for example with the cover 1204 encompassing (for example with upper and lower surfaces, typically as well as the side surfaces) the cushion element 1202, and with the cushion element 1202 comprising spacer fabric 1202b in contact with (and typically joined to) at least one surface of a fiber-foam layer 1202a). Furthermore, FIG. 12 shows in exploded view the spacer fabric layer in more detail, illustrating the upper and lower surfaces of mesh fabric 1291a and 1291b, as well as the interlinking lofted (e.g. 3D) warp-knit monofilament spacer yarn 1292 which joins (for example, being knit between) and spaces/separates the upper and lower mesh surfaces 1291a and 1291b.

Formation of disclosed topper embodiments might comprise one or more of the following steps: selecting cover material (for example, based on airflow rate, ability to resist shrinking and/or stretching during washing and/or drying, density/weight, etc.) and forming a cover (which for example, might initially be formed as an envelope operable to encompass a cushion element for a topper and open on one side (to allow for insertion of the cushion element), for example sized to one of the standard mattress sizes (for example, twin, full, queen, king, etc.)); selecting cushion material(s) (for example, based on airflow rate, ability to resist shrinking and/or stretching during washing and/or drying, density/weight, etc.) and forming a cushion (for example with spacer fabric and fiber-foam, which might be placed in contact and/or laminated to each other) sized to one of the standard mattress sizes and sized to fit in the cover; inserting the cushion element into the cover (or otherwise enveloping the cushion element with the cover, so that the cover encompasses the cushion element); closing (for example, with stitching) the cover (so that the cover completely encompasses the cushion element); and stitching through the cover (e.g. both the upper and lower surfaces of the cover) and the cushion element to form one or more compartments (e.g. permanently attaching the cover to the cushion element while also compartmentalizing the cushion). Typically, the cushion element might be compressed during stitching, so that the stitching holds the cushion element at those stitch points in compression, while also permanently affixing the cover to the cushion element (as well as the spacer fabric to the fiber-foam layer) at the stitching points. Typically, the stitching might comprise tack-and-jump stitching and/or channel stitching (and typically a combination, as previously discussed). And typically, one or more continuous lines of stitching would be used to form the compartments and/or permanently affix/attach the cover to the cushion element. In some embodiments, forming compartments might include forming a border compartment around the exterior of the topper (for example, with continuous stitching inset 1-3 inches from the edges) and/or forming one or more central compartments within the border compartment. In other embodiments, forming compartments might comprise forming a plurality of compartments without a border compartment (for example, with rectangular compartments extending across the width or length of the topper). The stitching process could form any of the quilting patterns discussed above, by way of non-limiting example.

While various embodiments in accordance with the principles disclosed herein have been shown and described above, modifications thereof may be made by one skilled in the art without departing from the spirit and the teachings of the disclosure. The embodiments described herein are representative only and are not intended to be limiting. Many variations, combinations, and modifications are possible and are within the scope of the disclosure. Alternative embodiments that result from combining, integrating, and/or omitting features of the embodiment(s) are also within the scope of the disclosure. Accordingly, the scope of protection is not limited by the description set out above, but is defined by the claims which follow, that scope including all equivalents of the subject matter of the claims. Each and every claim is incorporated as further disclosure into the specification and the claims are embodiment(s) of the present invention(s). Furthermore, any advantages and features described above may relate to specific embodiments, but shall not limit the application of such issued claims to processes and structures accomplishing any or all of the above advantages or having any or all of the above features.

Additionally, the section headings used herein are provided for consistency with the suggestions under 37 C.F.R. 1.77 or to otherwise provide organizational cues. These headings shall not limit or characterize the invention(s) set out in any claims that may issue from this disclosure. Specifically and by way of example, although the headings might refer to a “Field,” the claims should not be limited by the language chosen under this heading to describe the so-called field. Further, a description of a technology in the “Background” is not to be construed as an admission that certain technology is prior art to any invention(s) in this disclosure. Neither is the “Summary” to be considered as a limiting characterization of the invention(s) set forth in issued claims. Furthermore, any reference in this disclosure to “invention” in the singular should not be used to argue that there is only a single point of novelty in this disclosure. Multiple inventions may be set forth according to the limitations of the multiple claims issuing from this disclosure, and such claims accordingly define the invention(s), and their equivalents, that are protected thereby. In all instances, the scope of the claims shall be considered on their own merits in light of this disclosure, but should not be constrained by the headings set forth herein.

Use of broader terms such as comprises, includes, and having should be understood to provide support for narrower terms such as consisting of, consisting essentially of, and comprised. substantially of. Use of the term “optionally,” “may,” “might,” “possibly,” and the like with respect to any element of an embodiment means that the element is not required, or alternatively, the element is required, both alternatives being within the scope of the embodiment(s). Also, references to examples are merely provided for illustrative purposes, and are not intended to be exclusive.

While several embodiments have been provided in the present disclosure, it should be understood that the disclosed systems and methods may be embodied in many other specific forms without departing from the spirit or scope of the present disclosure. The present examples are to be considered as illustrative and not restrictive, and the intention is not to be limited to the details given herein. For example, the various elements or components may be combined or integrated in another system or certain features may be omitted or not implemented.

Also, techniques, systems, subsystems, and methods described and illustrated in the various embodiments as discrete or separate may be combined or integrated with other systems, modules, techniques, or methods without departing from the scope of the present disclosure. Other items shown or discussed as directly coupled or communicating with each other may be indirectly coupled or communicating through some interface, device, or intermediate component, whether electrically, mechanically, or otherwise. Other examples of changes, substitutions, and alterations are ascertainable by one skilled in the art and could be made without departing from the spirit and scope disclosed herein, and are therefore included within the scope of this disclosure.

Claims

1. A mattress topper, comprising:

a cushion element comprising a fiber-foam layer and a spacer fabric layer; and

a cover enclosing the cushion element and attached to the cushion element with stitching that divides the cushion element into a plurality of compartments;

wherein the fiber-foam layer comprises fibers distributed approximately evenly throughout foam;

wherein the fibers of the fiber-foam layer are the same material as the foam of the fiber-foam layer;

wherein the spacer fabric layer is laminated to a surface of the fiber-foam layer; and

wherein all of the plurality of compartments have approximately the same thickness of cushioning, resulting from being formed by division of the same cushion element by the stitching.

2. A mattress topper, comprising:

a cushion element comprising a fiber-foam layer and a spacer fabric layer; and

a cover enclosing the cushion element and attached to the cushion element with stitching that divides the cushion element into a plurality of compartments.

3. The topper of claim 2 wherein the spacer fabric layer underlies the fiber-foam layer; and wherein all of the plurality of compartments have approximately the same thickness of cushioning, resulting from being formed by division of the same cushion element by stitching.

4. The topper of claim 2 wherein the stitching is applied through both the fabric cover and the cushion element between top and bottom surfaces of the cover.

5. The topper of claim 2 wherein the stitching comprises a combination of tack-and-jump stitching and channel stitching, wherein the channel stitching connects points tacked by the tack-and-jump stitching, and wherein the channel stitching comprises 4 to 8 stitches per inch.

6. The topper of claim 2 wherein a plurality of the compartments are each sized and shaped identically, and are rectangular, triangular, or helical in shape.

7. The topper of claim 2 wherein the fiber-foam layer comprises fibers distributed approximately evenly throughout foam.

8. The topper of claim 2 wherein the fiber-foam layer comprises polyurethane foam and polyurethane fibers.

9. The topper of claim 2 wherein the fiber-foam layer has a thickness range of about 1-1.5 cm.

10. The topper of claim 2 wherein the spacer fabric layer is permanently attached to a surface of the fiber-foam layer.

11. The topper of claim 2 wherein the spacer fabric layer comprises a 3D warp knit fabric product.

12. The topper of claim 2 wherein the spacer fabric layer comprises an upper surface of mesh fabric, a lower surface of mesh fabric, and 3D spacer yarn layer between and connecting the upper and lower mesh fabric surfaces.

13. The topper of claim 12 wherein the spacer fabric upper and lower mesh fabric surfaces each comprise open mesh weave material; and wherein the upper and lower mesh fabric surfaces of the spacer fabric comprise an open mesh with openings approximately 0.5-1.0 cm. size.

14. The topper of claim 2 wherein the spacer fabric layer has a thickness of approximately 1-1.5 cm.

15. The topper of claim 2 wherein the cover comprise fabric.

16. The topper of claim 2 wherein the cushion element further comprises a second spacer fabric layer, and wherein the two spacer fabric layers sandwich the fiber-foam layer.

17. The topper of claim 16 wherein the second spacer fabric layer and the first spacer fabric layer are formed of the same material.

18. The topper of claim 2 further comprising a non-slip layer.

19. The topper of claim 18 wherein the non-slip layer is located on the side of the fiber-foam layer opposite the spacer fabric layer.

20. The topper of claim 18 wherein the non-slip layer forms the bottom surface of the cover.