Stretchable Mattress Cover

This application is a continuation of U.S. patent application Ser. No. 16/731,577, filed December 31, 019, which claims the benefit under 35 U.S.C. § 119(e) of U.S. Patent Application No. 62/856,485, entitled “MATTRESS COVERING,” filed 3 Jun. 2019, which is incorporated herein by reference in its entirety.

In general, a bed is a piece of furniture used as a location to sleep or relax. Many modern beds include a soft mattress on a bed frame. The mattress may include springs, foam material, and/or an air chamber to support the weight of one or more occupants. The mattress may include a mattress cover.

An example implementation of the subject matter described within this disclosure is a system with the following features. A bed has a mattress with a mattress top, a mattress bottom, and a mattress perimeter. The mattress includes a mattress cover surrounding the mattress. The mattress cover includes a first stretch fabric around the mattress perimeter of the mattress. The first stretch fabric has a first predominant stretch direction that is stretchable in a direction parallel to the mattress top. A multidirectional stretch fabric is positioned on the mattress top.

An example implementation of the subject matter described within this disclosure is a mattress cover with the following features. A first stretch fabric is positioned around a perimeter of a mattress. The first stretch fabric is configured to stretch predominantly in a direction parallel to a mattress top. A four-way stretch fabric is configured to be positioned on the mattress top.

An example implementation of the subject matter described within this disclosure is a method with the following features. A mattress cover with the following features is formed. A first stretch fabric is positioned around a perimeter of a mattress. The first stretch fabric is configured to stretch predominantly in a direction parallel to a mattress top. A four-way stretch fabric is configured to be positioned on the mattress top.

An example implementation of the subject matter described within this disclosure is a method with the following features. Mattress components of a cover are received to form a mattress. The cover includes a first stretch fabric positioned around a perimeter of the mattress. The first stretch fabric is configured to stretch predominantly in a direction parallel to a mattress top. A four-way stretch fabric is positioned on the mattress top. A second stretch fabric is positioned between the first stretch fabric and the four-way stretch fabric. The second stretch fabric is configured to stretch predominantly in a direction between an edge of the four-way stretch fabric and an edge of the first stretch fabric.

An example implementation of the subject matter described within this disclosure is a system with the following features. A bed has a mattress with a mattress top, a mattress bottom, and a mattress perimeter. The mattress includes a mattress cover surrounding the mattress. The mattress cover includes a first stretch fabric around the mattress perimeter of the mattress. A second stretch fabric is positioned on the mattress top. The second stretch fabric has different material properties than the first stretch fabric. A third stretch fabric is positioned on the mattress top and on the mattress perimeter. The third stretch fabric extends from the first stretch fabric to the second stretch fabric. The third stretch fabric has different material properties than the first and second stretch fabrics.

An example implementation of the subject matter described within this disclosure is a system with the following features. A bed has a mattress with a mattress top, a mattress bottom, and a mattress perimeter. The mattress includes a mattress cover surrounding the mattress. The mattress cover includes a first knit stretch fabric forming a mattress border around the mattress perimeter of the mattress. A second knit stretch fabric is positioned on the mattress top. The second knit stretch fabric has different material properties than the first knit stretch fabric and is configured to stretch to an amount suitable to allow a user to sink comfortably into the mattress when resting on the mattress top. A third knit stretch fabric is positioned on the mattress top and on the mattress perimeter to form a connection between the first knit stretch fabric and the second knit stretch fabric. The third knit stretch fabric has different material properties than the first and second knit stretch fabrics.

An example implementation of the subject matter described within this disclosure is a system with the following features. A bed has a mattress with a mattress top, a mattress bottom, and a mattress perimeter. The mattress includes a mattress cover surrounding the mattress. The mattress cover includes a first knit stretch fabric around the mattress perimeter of the mattress and a second knit stretch fabric positioned on the mattress top. The second knit stretch fabric has different material properties than the first knit stretch fabric. A first woven fabric is positioned around the mattress perimeter of the mattress proximate the mattress bottom. The first woven fabric is connected to the first knit stretch fabric.

Implementations previously described can include any, all, or none of the following features.

The mattress cover can further include a second stretch fabric positioned between the first stretch fabric and the multidirectional stretch fabric. The second stretch fabric has a second predomination stretch direction that is stretchable in a direction between an edge of the multidirectional stretch fabric and an edge of the first stretch fabric.

The second stretch fabric can be at least partially on the mattress top and at least partially on the mattress perimeter.

The mattress can include a left side and a right side. The first stretch fabric includes a first portion along the left side that is narrower than a height of the mattress and a second portion along the right side that is narrower than the height of the mattress.

The first portion and the second portion can be the same height.

The first portion and the second portion can include a bottom portion that is in-line with a bottom side of the mattress. The second stretch fabric extends between the multidirectional stretch fabric to the edge of the first stretch fabric. The second stretch fabric is both on the mattress top and at least partially along the left side and the right side.

A portion of the first stretch fabric at a head of the mattress and at a foot of the mattress can extend between the mattress top and a mattress bottom.

The first portion and the second portion each include a head section nearer a head of the bed and a foot section nearer the foot of the bed. Each of the head sections and the foot sections have a height substantially similar to a height of the mattress.

The first stretch fabric and the second stretch fabric can each stretch multidirectionally.

The first stretch fabric and the second stretch fabric can each stretch mono-directionally.

The first stretch fabric and the multidirectional stretch fabric can each include knit materials having different properties from one another.

A second stretch fabric can be positioned between the first stretch fabric and the four-way stretch fabric. The second stretch fabric is configured to stretch predominantly in a direction between an edge of the four-way stretch fabric and an edge of the first stretch fabric.

The second stretch fabric can be configured to be positioned at least partially on the mattress top.

The first stretch fabric can include a first portion configured to be positioned along a left side of the mattress. The first portion is narrower than a height of the mattress. The first stretch fabric includes a second portion configured to be positioned along a right side of the mattress. The second portion is less than the height of the mattress.

The first portion and the second portion can be the same height.

The first portion and the second portion can include a bottom portion configured to be in-line with a bottom side of the mattress. The second stretch fabric extends between the four-way stretch fabric to the edge of the first stretch fabric. The second stretch fabric is configured to be both on the mattress top and at least partially along the left mattress side and the right mattress side.

A third portion of the first stretch fabric can be configured to be at a head of the mattress and a fourth portion can be configured to be at a foot of the mattress. The third portion and the fourth portion are configured to extend between the mattress top and a mattress bottom.

The first portion and the second portion can each include a head section configured to be nearer a head of the mattress and a foot section configured to be nearer the foot of the mattress. Each of the head sections and the foot sections having a height substantially similar to a height of the mattress.

The mattress cover can further include a second stretch fabric positioned between the first stretch fabric and the four-way stretch fabric. The second stretch fabric is configured to stretch predominantly in a direction between an edge of the four-way stretch fabric and an edge of the first stretch fabric.

A foam tub and a mattress core can be received by the mattress cover.

The cover can be formed.

The third stretch fabric can be configured to stretch more than the first and second stretch fabrics.

The first stretch fabric can be configured to stretch less than the second and third stretch fabrics.

The first stretch fabric can have a thicker weight knit than the second and third stretch fabrics.

The first, second, and third stretch fabrics can each be multidirectional stretch fabrics with different stretch properties.

The first woven fabric can be laminated.

The first woven fabric can be a non-stretch woven fabric.

The mattress cover can further include a third knit stretch fabric configured to form a connection between the first knit stretch fabric and the second knit stretch fabric. The third knit stretch fabric has different material properties than the first and second knit stretch fabrics.

The subject matter described herein can allow for better mattress performance due to a better performing mattress cover. Alternatively or in addition, the subject matter described herein can allow for a better fitting and/or functioning mattress cover, which allows for improved aesthetics because the cover stays in place and wrinkles less. The mattress cover can include different panels of different stretch materials with different material properties suitable for particular functions combined in a way to improve mattress functionality.

Other features, aspects, and potential advantages will be apparent from the accompanying description and figures.

Like reference symbols in the various drawings indicate like elements.

Traditional mattress ticking that is used as fabric that covers a mattress often has very little stretch. Consequently, it pulls on interior mattress components (such as foam) when an occupant lays on the mattress. A boarder of the cover can be a woven material with little or no stretch properties and can retain unsightly wrinkles after it is compressed by the occupant. These two materials (ticking and boarder) are often sewn together to form a cover for the mattress.

The subject matter of this disclosure relates to a mattress cover that reduces permanent deformation and wear of foam material of a mattress. While described in the context of foam material (such as a foam tub), the subject matter described herein can easily be applied to mattresses having other materials (such as spring tubs and other spring material) as well. The foam tub (or spring tub) can surround a mattress core. In some embodiments, the foam tub (or spring tub) can surround one or more inflatable air chambers used as the mattress core. In some embodiments, the foam tub (or spring tub) can surround one or more spring and/or foam components used as the mattress core. In other embodiments, the foam tub (or spring tub) can be replaced with one or more other mattress components (i.e. foam, springs, air chambers, and/or other components).

A mattress cover can have multiple panels made of materials that are configured to function for a certain purpose. For example, a monofilament spacer material can be used for the sleep surface directly underneath where the occupant would typically lay. This material can have multidirectional (i.e. four-way) stretch properties to help the foam and air chamber of the bed to conform to and supports the unique contours of the occupant's body. Such a spacer also could potentially have a positive impact on the occupant's temperature by allowing for airflow. A multidirectional or predominantly mono-directional (i.e. two-way) stretch fabric around the perimeter of the sleep surface helps the cover return to shape after the occupant gets out of the bed. The perimeter material attaches to a boarder material that also has multidirectional or predominantly mono-directional (two-way) stretch properties around the bed to help accommodate foam tolerance and recover from flexing and compression. A woven material can be positioned below and attached to the border material on the sides of the mattress. The woven material can be non-stretch woven material that has limited or no capacity for stretching and recovery and can be suitable for structurally retaining a bottom of the mattress. In some embodiments, a mattress cover can include panels of fabric including one, more than one, or all of these materials. In some embodiments, one or more panels of fabric can be different as suitable for the application.

is a perspective view of a mattresshaving an example mattress coverinstalled over the mattress. The mattressincludes a mattress top, a mattress bottom, and a mattress perimeter. The mattress coversurrounds the mattressand includes a stretch fabricaround the mattress perimeter. The stretch fabricis stretchable in a direction parallel to the mattress top. The stretch fabrichelps accommodate foam tolerance and recovery from flexing and compression. Such stretching and compression can be caused by general use of the mattress, using an adjustable base with the mattress, shipping the mattress, or any other scenarios that can cause foam deformation to the mattress edges. A stretch fabricis positioned on the mattress top. The stretch fabric, configured to be positioned on the mattress top, allows for sufficient stretch for the mattressto fully support an occupant without interference from the mattress cover. In some implementations, the stretch fabriccan include a spacer fabric with a monofilament spacer material. Spacer fabrics contain a combination of textile sheets and distance fibers, with a porous structure that can offer high absorption capacities for textile materials. The distance fibers can be monofilament polyester fibers with a sufficient stiffness to maintain spacing within the fabric. As such, spacer fabrics can resist high pressure and can transport fluid and heat, for example, sweat and body heat. In such an implementation, the spacer material allows for at least a small amount of airflow to help keep the occupant cool and dry. In some implementations, the mattress coveralso includes a stretch fabricpositioned between the stretch fabricand the stretch fabric. The stretch fabricis stretchable in a direction between a stretch fabric edgeand a stretch fabric edge. As illustrated, the stretch fabricis at least partially on the mattress topand partially along the mattress perimeter. The stretch fabrichelps the mattress coverreturn to shape after an occupant leaves the mattress.

Different panels of fabric can be attached to each other at one or more seams, such as via sewing/stitching. For example, the stretch fabric, the stretch fabric, the stretch fabriccan be sewn together forming multiple seams. Seams can also be included by stitching together panels of the same kind of fabric. For example, the stretch fabricon the mattress topcan be formed of two panels of the stretch fabricsewn together with a seam down the middle, such as illustrated in. Alternatively, the stretch fabriccan be formed via a single panel of material, with no seam down the middle of the mattress. In further alternative embodiments, the number and shape of fabric panels can be further varied from the illustrated examples.

The mattress coverincludes a left sideand a right side. In some implementations, the stretch fabricincludes a “waterfall” or wingaround an upper corner of the mattress, stretching partially on the mattress topand partially along the mattress perimeter. The stretch fabrichas a first portion (not shown) along the left sidethat is narrower than a height of the mattress and a second portionalong the right sidethat is narrower than the height of the mattress. The first portion and the second portioncan be the same height (within standard manufacturing tolerances). The stretch fabricextends between the stretch fabricto the stretch fabric edge. The stretch fabricis both on the mattress topand at least partially along the left sideand the right side. A portion of the stretch fabricat a headof the mattress and at a footof the mattressextends between the mattress topand a mattress bottom. The first portion and the second portioneach include a head sectionnearer a headof the bed and a foot sectionnearer the footof the bed. Each of the head sectionsand the foot sectionshave a height substantially similar (within standard manufacturing tolerances) to a height of the mattress.

A bottom fabricextends from a bottom edge of the stretch fabricto a bottom of the mattress. The bottom fabriccan be a substantially non-stretch woven material configured to substantially resist stretching or to prevent stretching. By resisting stretching, the bottom fabriccan help provide rigidity to a bottom portion of the mattress, which can be beneficial in embodiments of the mattresshaving an upside-down foam or spring tub and in other embodiments of the mattressthat benefit from substantially non-stretch woven material. In some embodiments, the bottom fabriccan include the substantially non-stretch woven material in combination with a laminate material that can provide some rigidity as well as fire resistance properties.

In embodiments that do not benefit from a substantially non-stretch woven material being used, the bottom fabriccan include a different material. For example, in some embodiments the bottom fabriccan include a knit material or a stretch knit material. A stretch knit material can be used in embodiments that benefit from having the bottom fabricbeing stretchable by a small amount or even a large amount. In some embodiments, the bottom fabriccan be a knit material with little or no ability to stretch.

Some or all of the stretch fabric, the stretch fabric, and the stretch fabriccan be different fabrics having different properties. For example, the stretch fabric, the stretch fabric, and the stretch fabriccan each include knit materials that are configured to stretch and resiliently rebound/recover to shape, but can have different properties such as knit thickness, capacity for stretching, etc. In some embodiments, the stretch fabriccan include a knit material with a relatively thick weight knit and a relatively limited capacity for stretching. The stretch fabriccan allow for some stretching on the sides of the mattresswhile also providing a desirable level of stiffness and support for the mattress. The stretch fabriccan include a knit material with a relatively thin weight knit and a relatively large capacity for stretching. The stretch fabriccan be configured to stretch enough to allow a user lying on the mattressto sink into the foam or other material under the stretch fabricwithout the stretch fabricproviding an undesirable amount of tension. The stretch fabriccan include a spacer material, or can be made without a spacer material. The stretch fabriccan include a knit material with a relatively thin weight knit and a relatively large capacity for stretching. The stretch fabriccan be configured to resiliently connect the stretch fabricon top of the mattressto the stretch fabricon the sides of the mattress. The stretch fabriccan be configured to stretch more than both of the stretch fabricsandso as to substantially keep the stretch fabricsandunder tension without pulling with an undesirably high amount of tension. In other embodiments, the knit thickness, capacity for stretching, and other material properties of the stretch fabric, the stretch fabric, and the stretch fabriccan be varied as suitable for the application.

In some embodiments, the stretch fabric, the stretch fabric, and the stretch fabriccan have multidirectional (e.g. four-way) stretch properties. In some of such embodiments, one or more of the stretch fabric, the stretch fabric, and the stretch fabriccan have a dominant stretch direction. For example, the stretch fabriccan stretch predominantly in a direction around a perimeter of the mattress, with less stretching in a vertical direction. The stretch fabriccan stretch predominantly in a direction extending from the stretch fabricto the stretch fabric, with less stretching in a perpendicular direction. The stretch fabriccan stretch either equally or substantially equally in each direction.