Note: Descriptions are shown in the official language in which they were submitted.
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MATTRESS TOPPER COMPRISING POCKETED SPRING
ASSEMBLY WITH AT LEAST ONE CUSHIONING LAYER
Background of the Invention
[0001] This invention relates generally to bedding or seating
products
and, more particularly, to a mattress topper or pad for use in on a finished
mattress.
[0002] Traditionally, toppers for mattresses have consisted of
relatively
thin members which may be removed from the mattress for a variety of
purposes. U.S. Patent No. 6,009,579 discloses a topper for a feather bed.
U.S. Patent No. 6,922,862 discloses a topper designed to be placed on top of a
conventional mattress.
[0003] One drawback of known toppers for use with conventional
mattresses is that the toppers are not durable enough and may have to be
replaced frequently.
[0004] In order to achieve greater durability in a topper adapted to
be
removed from a bedding or seating product, such as a mattress, it would be
desirable to include a pocketed spring assembly into the topper. Therefore,
making a topper having a pocketed spring assembly incorporated therein, the
topper being sold separately from a mattress, would be desirable.
Summary of the Invention
[0005] This invention provides a mattress pad or topper which may be
sold separately from a finished bedding or seating product, such as a
mattress.
The present invention is not intended to be limited for use with any
particular
bedding or seating product. For example, the mattress topper of the present
invention may be used with a mattress having an innerspring core or a foam
core or any combination thereof.
[0006] According to one aspect of the present invention, a mattress
topper may be used with any mattress. The mattress topper comprises a
bucket or casing comprising a bottom and sides. A pocketed spring assembly
is located inside the bucket. At least one cushioning layer may be located
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above the pocketed spring assembly. The mattress topper further comprises a
quilted top layer and a skirt adapted to fit around a mattress. The bucket,
skirt
and quilted top layer are sewn together. In some instances, inner edges of the
bucket, skirt and quilted top layer may be taped together before being sewn
together.
[0007] The skirt of the mattress topper may have an elastic band or
draw
string sewn therein to better secure the mattress topper around the mattress.
[0008] One or more of the cushioning layers may be polyurethane or
latex or memory foam or any other type of foam. One or more of the
cushioning layers may alternatively or collectively be a layer of fiber batt
or
down for insulation purposes. Another type of cushioning layer may be a gel
layer.
[0009] In some versions of the mattress topper, cushioning materials
are
located only above the pocketed spring assembly. However, in other versions
of the mattress topper, cushioning or insulating materials may be located
above
and below the pocketed spring assembly.
[0010] According to another aspect of the present invention, a
mattress
may be used in combination with a mattress topper. The mattress topper may
be removed from the mattress without disturbing the mattress. The mattress
topper may comprise a casing surrounding a pocketed spring assembly; at
least one cushioning layer and a quilted top layer. The mattress topper may
further comprise a skirt sized or adapted to fit around or surround the
mattress.
The skirt may have an elastic band or drawstring at the bottom of the skirt.
The
cushioning layer may include one or more layers of foam and/or fiber. The
cushioning layer(s) may cover one or opposed surfaces of the pocketed spring
assembly. The casing, skirt and quilted top layer may be sewn together.
[0011] Although several types of mattress topper have been described
herein, any of the mattress toppers shown or described herein may be used in
any bedding or seating product, including a mattress. For example, the topper
may be used in a seat cushion, such as a car seat.
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Brief Description of the Drawings
[0012] The objectives and features of the invention will become more
readily apparent from the following detailed description taken in conjunction
with the accompanying drawings in which:
[0013] Fig.1 is a perspective view of a mattress topper according to
one
embodiment on top of a mattress;
[0014] Fig. 2 is a perspective view, partially broken away, of the
mattress
topper of Fig. 1 pulled away from the mattress of Fig. 1;
[0015] Fig. 3 is a cross-sectional view taken along the line 3-3 of
Fig. 1,
the mattress being shown in phantom;
[0016] Fig. 4 is an enlarged cross-sectional view of the encircled
area 4
of Fig. 3;
[0017] Fig. 4A is an enlarged view like Fig. 4 of an alternative
seam;
[0018] Fig. 5 is a perspective view, partially broken away, of
another
embodiment of mattress topper pulled away from a mattress;
[0019] Fig. 6 is a cross-sectional view of the mattress topper of
Fig. 5 on
a mattress, the mattress being shown in phantom;
[0020] Fig. 7 is a perspective view, partially broken away, of
another
embodiment of mattress topper pulled away from a mattress;
[0021] Fig. 8 is a cross-sectional view of the mattress topper of
Fig. 7 on
a mattress, the mattress being shown in phantom;
[0022] Fig. 9 is a perspective view, partially broken away, of
another
embodiment of mattress topper pulled away from a mattress;
[0023] Fig. 10 is a cross-sectional view of the mattress topper of
Fig. 9
on a mattress, the mattress being shown in phantom;
[0024] Fig. 11 is a perspective view, partially broken away, of
another
embodiment of mattress topper pulled away from a mattress;
[0025] Fig. 11A is an enlarged view of the encircled area of Fig. 11;
and
[0026] Fig. 12 is a cross-sectional view of the mattress topper of
Fig. 11
on a mattress, the mattress being shown in phantom.
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Detailed Description of the Invention
[0027] Referring to the drawings and, particularly to Fig. 1, a
mattress
topper 10, according to one embodiment of this invention, is shown in
connection with a bedding or seating product in the form of a mattress 12. As
shown in Fig. 1, the mattress 12 has a longitudinal dimension or length L and
a
transverse dimension or width W. Although the length L is shown as being
greater than the width W, they may be identical. As shown in Fig. 1, the
combination of mattress topper 10 and mattress 12 has a height H.
[0028] The mattress 12 may be any known mattress and is not intended
to be limited to any particular mattress. For example, the mattress 12 may
include a spring core or spring assembly or may be entirely foam. The mattress
topper 10 of the present invention may be used in connection with any
adjustable bed mattress or sofa sleeper mattress also.
[0029] The mattress topper 10 need not be sold with a mattress or
other
bedding or seating product. The mattress topper 10 may be sold separately
and replaced at any desired time. Fig. 2 illustrates one embodiment of
mattress topper 10 separated from a mattress 12. As shown in Figs. 2 and 3,
the mattress topper 10 comprises a bucket or casing 14 having a bottom 16
and sides 18. As shown in Fig. 4, an upper portion 20 of each bucket side 18
may be turned inwardly at location 22 to a generally horizontal orientation
for
assembly purposes, as described below.
[0030] As best shown in Figs. 2 and 3, the mattress topper 10 further
comprises a pocketed spring assembly 24 inside the bucket or casing 14. As
shown in Fig. 2, pocketed spring assembly 24 comprises a plurality of
longitudinally extending strings 26 of individually pocketed springs joined
together and extending from end-to-end of the mattress topper 10.
Alternatively, the strings of individually pocketed springs may extend
transversely or from side-to-side inside the bucket 14 of the mattress topper
10.
As shown in Fig. 3, each string of pocketed springs 16 comprises a row of
individual fabric pockets 28, each containing at least one spring 30. Although
one pocketed spring assembly is illustrated, any known pocketed spring
assembly may be used including the one disclosed in U.S. Patent No.
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8,087,114, for example. Any of the mattress toppers shown or described
herein are not intended to limit the pocketed spring assembly incorporated
therein.
[0031] As shown in Figs. 2 and 3, mattress topper 10 further
comprises a
first cushioning layer of polyurethane foam 32 below the pocketed spring
assembly 24 inside the bucket or casing 14 immediately above the bottom 16 of
the bucket or casing 14. The mattress topper 10 further comprises a second
cushioning layer of polyurethane foam 34 above the pocketed spring assembly
24. Each of the cushioning layers of polyurethane foam 32, 34 may be any
desired depth. However, in one embodiment, the depth of each cushioning
layer of polyurethane foam 32, 34 is one-half inch. As an alternative, any
type
of foam, including but not limited to memory foam, may be used for one or both
of the cushioning layers 32, 34.
[0032] Another component of the mattress topper 10 is a quilted top
layer or fiber panel 36. As best shown in Figs. 3 and 4, this quilted fiber
panel
36 comprises an outer fabric layer 38 surrounding a fiber interior 40 sewn
together along seams 42 which assume any desired pattern.
[0033] As shown in Figs. 2 and 3, mattress topper 10 further
comprises a
skirt 44 adapted to fit around mattress 12. At its bottom, the skirt 44 has an
elastic band 46 adapted to fit underneath mattress 12 so that the skirt 44
stays
on top of the mattress 12. As shown in Fig. 3, the skirt 44 extends from a
combination seam 48 shown in detail in Fig. 4 downwardly along the sides 50 of
the mattress 12 and along the lower surface 52 of the mattress 12.
[0034] Fig. 4 illustrates the details of the combination seam 48
which
joins together the elements of the mattress topper 10 and, more particularly,
the
bucket 14, the skirt 44 and the quilted upper layer 36. As shown in Fig. 4,
tape
54 is wrapped around outer edges of the bucket 14, the skirt 44 and the
quilted
upper layer 36. The combination seam 48 joins together the upper generally
horizontally oriented portion 20 of sidewalls 18 of bucket 14 below a bent
generally horizontally oriented upper portion 56 of skirt 44 and an outer
generally horizontally oriented portion 58 of the quilted top layer or fiber
panel
36. The generally horizontally oriented portion 58 of the quilted top layer or
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fiber panel 36 is located above the generally horizontally oriented upper
portion
56 of skirt 44.
[0035] Fig. 4A illustrates the details of another combination seam
48a
which may join together the elements of the mattress topper 10 and, more
particularly, the bucket 14, the skirt 44 and the quilted upper layer 36. As
shown in Fig. 4A, tape 54 is wrapped around outer edges of the bucket 14, the
skirt 44 and the quilted upper layer 36. The combination seam 48a joins
together an edge portion 20a of sidewall 18 of bucket 14, an edge portion 56a
of skirt 44 and an edge portion 58a of the quilted top layer or fiber panel 36
along with the tape 54. As shown in Fig. 4A, the edge portion 58a of the
quilted
top layer or fiber panel 36 is located between the edge portion 20a of
sidewall
18 of bucket 14 and the edge portion 56a of skirt 44. Once, the edge portion
58a of the quilted top layer 36 and the edge portion 20a of sidewall 18 of
bucket 14 and the edge portion 56a of skirt 44 are sewn together with the tape
54 with combination seam 48a, the sidewall 18 of bucket 14 is bent at location
66 downwardly to form an inverted U-shape outside the combination seam 48a.
Similarly, the skirt 44 is bent at location 68 downwardly to form an inverted
U-
shape outside the combination seam 48a.
[0036] Figs. 5 and 6 illustrate an alternative embodiment of mattress
topper 10a identical to the mattress topper 10, but omitting the lower
cushioning
layer 32.
[0037] Figs. 7 and 8 illustrate an alternative embodiment of mattress
topper 10b identical to the mattress topper 10, but including two additional
cushioning layers 60, 62. Each of the cushioning layers 60, 62 comprises fiber
batt. As illustrated in Fig. 8, cushioning layer 60 is located between the
quilted
top layer or fiber panel 36 and the upper foam cushioning layer 34. Similarly,
cushioning layer 62 is located between the bottom 16 of the casing 14 and the
lower foam cushioning layer 32.
[0038] Figs. 9 and 10 illustrate an alternative embodiment of
mattress
topper 10c identical to the mattress topper 10, but having a non-quilted top
layer 64 in place of a quilted top layer. The non-quilted top layer 64 may be
made of any desired material. In either of the combination seams 48, 48a
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shown in Figs. 4 and 4A, a non-quilted top layer 64 may be inserted in place
of
a quilted top layer.
[0039] Figs. 11 and 12 illustrate an alternative embodiment of
mattress
topper 10d identical to the mattress topper 10, but having a different
pocketed
spring assembly 24d in place of pocketed spring assembly 24. The pocketed
spring assembly 24d need not be made of strings of individually pocketed
springs joined together. Rather the pocketed spring assembly 24d may
comprise a blanket of individually pocketed springs, each spring 30d being in
a
pocket 28d. Although the springs 30d shown in pockets 28d are illustrated as
being shorter than the springs 30 in pockets 28 of the mattress topper 10,
they
may be any desired size. As shown in Fig. 12, pockets 28d comprise upper and
lower plies 66, 68, respectively, joined together along intersecting seams 70.
As shown in Fig. 11A, the spaced seams 70 intersect each other at
intersections 72 and assume a checkerboard type of pattern. Some of the
seams 70 extend transversely or from side-to-side while other seams 70 extend
longitudinally or from head-to-foot.
[0040] One of ordinary skill in the art will readily recognize that
the
alternative embodiments of the mattress topper shown herein are exemplary
only of a wide variety of alternative configurations that are readily possible
within the scope of this invention.
[0041] From the above disclosure of the general principles of the
present
invention, and the preceding detailed description of at least one preferred
embodiment, those skilled in the art will readily comprehend the various
modifications to which this invention is susceptible. Therefore, we desire to
be
limited only by the scope of the following claims and equivalents thereof.
[0042] We claim:
