Note: Descriptions are shown in the official language in which they were submitted.
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Mattress cover
The invention relates to a mattress cover that comprises an upper face (top
face) and a lower
face (bottom face) and is intended to receive a mattress core.
Mattress covers that are generally known in practice are usually intended to
tightly encase a
rectangular mattress core, the upper face and lower face of which have a
length and a width
that are large compared with the height and form a lying surface for a person.
The mattress cover generally consists of a fabric region that forms the upper
face and a fabric
region that forms the lower face. In the case of a removable mattress cover
that allows the
mattress core to be inserted into the mattress cover or allows the mattress
cover to be removed
from the mattress core, a fastener, for example in the form of a zip fastener,
is provided for this
purpose, which fastener extends at least in part on the longitudinal sides and
on the transverse
sides when put onto the mattress core.
Depending on the embodiment of the mattress cover, the fabric regions of the
upper face and
lower face may be formed by individual fabric panels that form the relevant
lying surface or the
lower face and which are interconnected by fabric strips that form
longitudinal sides and the
transverse sides. Fabric strips of this kind are generally connected to the
fabric panels of the
upper face and lower face by means of stitched seams, it being possible for
the stitched seams
to be covered by an edge binding or a welting band.
In the case of mattress covers known in practice, ventilation strips
consisting of a material that is
highly permeable compared with the further mattress cover fabric are in
addition often used on
the longitudinal sides and transverse sides, since usual cover fabrics for a
mattress cover
usually have a low degree of air permeability and the mattress core is
otherwise inadequately
ventilated.
DE 10 2008 058 134 83 B3 for example discloses using warp-knitted three-
dimensional spacer
fabrics as the highly air-permeable material for a ventilation strip of this
kind, which warp-knitted
spacer fabrics have a high degree of air permeability while having relatively
good stability.
DE 20 2012 005 880 U1 furthermore discloses designing a mattress cover in two
parts, such
that one side is formed of a viscoelastic foam, as a winter cover, and the
other side is formed of
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warp-knitted 3D spacer fabrics, as a summer cover which, on account of the
greater
breathability thereof, produces a better microclimate for the sleeper.
A disadvantage in this case, however, is that warp-knitted 3D spacer fabrics
are relatively stiff
and inflexible, which restricts the design of the lying comfort for the
sleeper.
DE 202 01 919 U1 discloses the use of a weft-knitted spacer fabric for
mattress and seat
covers, as well as linings having outside and inside textiles surfaces that
consist of a textile that
has been shrunk in a washing process, and a spacer structure therebetween, the
spacing
threads of which are formed, on the mutually facing inner surfaces, by knitted
monofilament or
multifilament threads, one or both of the external surfaces being provided
with a jacquard
pattern.
On account of the different structure thereof, weft-knitted spacer fabrics are
more stretchable
than warp-knitted spacer fabrics, with the result that a mattress cover formed
having a weft-
knitted spacer fabric makes it possible, in principle, to increase the comfort
for a user, since said
mattress cover can be formed so as to be soft, springy and to have a pleasant
feel.
It has been found in practice, however, that there is a need to improve the
known weft-knitted
spacer fabrics with respect to the breathability and the lying comfort.
An object of the present invention may therefore be to provide for a mattress
cover of the type
mentioned at the outset, which cover is particularly breathable, forms a
comfortable and soft
lying surface, and allows for simple workability.
This object is achieved, according to the invention, by a mattress cover
comprising a cover
fabric that forms an upper face and/or a lower face that are each dimensioned
as a lying surface
for a user, in that the cover fabric is formed having a weft-knitted 3D (three-
dimensional) spacer
fabric at least on the outer face thereof and comprises a honeycombed mesh
structure having
outwardly open recesses on the outer face thereof.
The invention therefore makes use of the advantages of a weft-knitted spacer
fabric which
typically comprises a spacer structure having stitches of knitted monofilament
or multifilament
threads, and combines said advantages with the advantages of a honeycombed
mesh structure
that allows particularly efficient air circulation and moisture removal from
the mattress.
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In this case, however, the honeycombed, outwardly open recesses are
advantageous not only
with respect to air exchange and moisture removal as well as compensation of
temperature
fluctuations in general, but also allow for increased springiness which
provides a user with a soft
feel and in addition allows the mattress cover to be optimally adapted to the
user lying thereon
without said user being disturbed in the process by coarse spacing threads
that are often
noticeable in weft-knitted spacer fabrics.
A mattress cover of this kind can be produced in a simple manner, for example
on a large
circular knitting machine operating in accordance with a 3-way technique, at a
high throughput
over time and thus very economically.
In this case, the recesses of the mesh structure are preferably provided so as
to be in a regular
arrangement on the outer face of the cover fabric, an irregular arrangement,
for example
forming a pattern, also being conceivable, however.
The honeycombed, outwardly open recesses may be variable in terms of the
geometry thereof,
and thus the open cross section thereof may be round or oval or angular for
example.
In a preferred embodiment of the invention, the cover fabric consisting of
weft-knitted 3D spacer
fabric is formed in at least two layers, having an upper layer that forms the
outer face, and a
preferably polyester fibrous material woven fabric layer that forms an inner
layer.
In this case, the inner layer forms a smooth woven fabric layer that may also
be jacquarded and
provided with a pattern for example, and on which woven fabric layer the upper
layer of the
weft-knitted 3D spacer fabric made of textured, twisted yarn, in particular
multifilament yarn, is
built up outwardly.
In this case, the honeycombed recesses may extend at least substantially over
the entire
thickness of the upper layer, i.e. from the outer face as far as the inner
layer or close thereto, in
order to allow for optimum conditioning with regard to the air and moisture
exchange between
the two sides of the cover fabric. Moreover, the depth of the honeycombed
recess increases the
softness of the weft-knitted 3D spacer fabric upper layer, as a result of
which an improved feel
can be achieved.
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If the cover fabric is formed in three layers, comprising a middle layer that
is knitted to the upper
layer and comprises a monofilament yarn as a filling material, stabilisation
and volumisation
(increase in volume) of the weft-knitted 3D spacer fabric, which volumisation
is frequently
desired in terms of feel, can be achieved at the same time as a high degree of
air and moisture
permeability. According to a preferred embodiment, the monofilament yarn may
be formed of
polyester, but other synthetic fibres, such as fibres formed of polyamide, are
also possible
therefor.
In order to provide the outwardly facing surface of the weft-knitted spacer
fabric with a
particularly smooth and pleasant feel, the surface surrounding the honeycombed
recesses may
be formed by particularly fine knitting stitches.
Tests have shown that it is particularly advantageous, with respect to comfort
and micro-
conditioning, for the upper layer of the weft-knitted spacer fabric to have a
weight portion of
cover fabric of from 50% to 70%, in particular from 55% to 60%.
In this case, the inner layer may have a weight portion of cover fabric of
from 20% to 30%, in
particular from 25% to 30%.
When a filling material is used, optimum results in terms of air permeability,
stabilisation and
volumisation were identified when the middle layer has a weight portion of
cover fabric of from
10% to 20%, in particular from 15% to 20%.
In this case, the cover fabric may have a weight of from 200 g/m2 to 300 g/m2,
as a result of
which it has the required durability and is at the same time easy to handle,
in terms of the
weight thereof, both during production and during use.
The mattress cover may be designed so as to be the same on all faces, i.e. on
the upper face,
on the lower face and on the longitudinal and transverse sides that are formed
when a mattress
core is inserted, it also being conceivable in principle, however, for
different faces of the
mattress cover to also be designed differently.
Designing all the faces so as to be the same allows for particularly efficient
production, the high
level of breathability of the cover fabric also making it possible to omit a
ventilation band on the
transverse and longitudinal sides, which band is often present in known
mattress covers.
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In order to allow a mattress core to be inserted and removed, it is
advantageous for the
mattress cover to comprise a fastener, in particular a zip fastener, that is
peripheral at least in
part. Furthermore, in order to make it easier to handle the mattress that is
covered by the
mattress cover, grips may be sewn onto the mattress cover.
Further advantages and advantageous developments of the invention can be found
in the
claims and in the embodiment that is described schematically and with
reference to the
drawings.
In the drawings:
Fig. 1 is a schematic perspective view of a mattress cover that is designed
according to the
invention and has been put onto a mattress core;
Fig. 2 is a highly simplified plan view of a detail of an outer face of the
mattress cover; and
Fig. 3 is a schematic cross-sectional view through a region of a cover fabric
of the mattress
cover.
With reference to Fig. 1, a mattress cover 1 can be seen in a state when
stretched over a
mattress core 2, the mattress cover 1 forming, for a user sleeping thereon, a
first lying surface
on an upper face 3 and a second lying surface on an opposing lower face 4.
The mattress cover 1 is formed by the same cover fabric 5 all the way around,
lateral transverse
surfaces 6 and longitudinal surfaces 7 also transitioning seamlessly, in the
present case, into
the upper face 6 and lower face 7.
Deviating therefrom, however, in other embodiments the surfaces of the cover
fabric 5 may also
be separated by stitched seams and a welting band may optionally also be
provided.
In order to insert and remove the mattress core 2, a peripheral fastener 8 in
the form of a zip
fastener is sewn into the mattress cover 1 on the transverse surfaces 6 and
longitudinal sides 7.
In addition, a plurality of grips 9 for lifting the mattress core 2,
encompassed by the mattress
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cover 1, are provided on the lateral longitudinal surfaces 7, just one of said
grips or handles 9
being shown by way of example.
As can be seen in a detail X in Fig. 1, which detail represents the entire
surface of the mattress
cover 1, and in Fig. 2 and Fig. 3, the cover fabric 5 is formed having a weft-
knitted 3D spacer
fabric 10 as far as the outer face 11 thereof, the cover fabric 5 having a
honeycombed mesh
structure having a regular, delicate arrangement of outwardly open recesses
12. In this case,
the recesses 12 preferably have an oval cross section towards the outside,
which cross section
can be approximately 2 mm to 4 mm wide and approximately 3 mm to 5 mm long
when
unstretched. The widths of the weft-knitted spacer fabric 10 material
projections 13 located
between the mutually offset and regular recesses 12 are at least approximately
the same.
In the present case, the cover fabric 5 of the mattress cover 1 is designed as
a three-layer weft-
knitted 3D spacer fabric comprising an upper layer 14 that forms the outer
face 11 and is formed
of a textured, twisted polyester multifilament yarn; a middle layer 15 that is
made of a coarse
polyester multifilament yarn, is knitted to the upper layer 14, jointly forms
the weft-knitted spacer
fabric 10 and is used as a filling material; and a layer of smooth polyester
yarn that is knitted to
the upper layer 14 and the middle layer 15 and forms an inner layer 16.
In this case, the upper layer 14 has a finely knitted structure 17 on the
outer face 11 thereof,
which structure provides the surface with a soft feel.
With regard to the thickness, in the advantageous embodiment shown, the upper
layer 14 is
dimensioned so as to occupy at least 70% to 80% of the total thickness of the
cover fabric 5, in
order make use, as far as possible, of the microclimatic advantages of the
weft-knitted spacer
fabric 10.
In order to allow as much air circulation as possible and optimal moisture
removal at the outer
face, the honeycombed recesses 12 extend substantially over the thickness of
the upper layer
14 and of the middle layer 15 until adjacent to the lower layer 16 such that,
as a result of the
recesses 12, the cover fabric is very flexible and stretchable in the width
direction. The
springiness in the height direction achieves a softness which can be defined,
according to the
desired degree of softness, by means of the filling material of the middle
layer 14.
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Of course, depending on the application, the cover fabric 5 can be produced
using all known
methods for weft-knitting spacer fabrics on circular knitting machines, and
using all known
finishing methods, such as a washing, bleaching and shrinking process
following the knitting
process.
