US20230160113A1 - Multilayer weft-knitted fabrics for mattress covers - Google Patents
Multilayer weft-knitted fabrics for mattress covers Download PDFInfo
- Publication number
- US20230160113A1 US20230160113A1 US17/991,496 US202217991496A US2023160113A1 US 20230160113 A1 US20230160113 A1 US 20230160113A1 US 202217991496 A US202217991496 A US 202217991496A US 2023160113 A1 US2023160113 A1 US 2023160113A1
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- United States
- Prior art keywords
- fabric
- cover
- mattress
- knitted
- upper layer
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- 239000004744 fabric Substances 0.000 title claims abstract description 113
- 125000006850 spacer group Chemical group 0.000 claims abstract description 29
- 239000000463 material Substances 0.000 claims description 24
- 229920000728 polyester Polymers 0.000 claims description 7
- 230000002093 peripheral effect Effects 0.000 claims description 3
- 239000004952 Polyamide Substances 0.000 claims description 2
- 229920002647 polyamide Polymers 0.000 claims description 2
- 229920006149 polyester-amide block copolymer Polymers 0.000 claims 1
- 239000004753 textile Substances 0.000 abstract description 3
- 230000008901 benefit Effects 0.000 description 6
- 238000000034 method Methods 0.000 description 6
- 238000009940 knitting Methods 0.000 description 5
- 239000002759 woven fabric Substances 0.000 description 5
- 230000035699 permeability Effects 0.000 description 4
- 238000009423 ventilation Methods 0.000 description 3
- 241001669679 Eleotris Species 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 230000006641 stabilisation Effects 0.000 description 2
- 238000005406 washing Methods 0.000 description 2
- 238000004061 bleaching Methods 0.000 description 1
- 230000003750 conditioning effect Effects 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 230000018109 developmental process Effects 0.000 description 1
- 239000002657 fibrous material Substances 0.000 description 1
- 239000006260 foam Substances 0.000 description 1
- 230000001788 irregular Effects 0.000 description 1
- 229920002994 synthetic fiber Polymers 0.000 description 1
Images
Classifications
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- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C31/00—Details or accessories for chairs, beds, or the like, not provided for in other groups of this subclass, e.g. upholstery fasteners, mattress protectors, stretching devices for mattress nets
- A47C31/10—Loose or removable furniture covers
- A47C31/105—Loose or removable furniture covers for mattresses
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04B—KNITTING
- D04B1/00—Weft knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
- D04B1/22—Weft knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes specially adapted for knitting goods of particular configuration
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
- A47C27/002—Mattress or cushion tickings or covers
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C31/00—Details or accessories for chairs, beds, or the like, not provided for in other groups of this subclass, e.g. upholstery fasteners, mattress protectors, stretching devices for mattress nets
- A47C31/006—Use of three-dimensional fabrics
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04B—KNITTING
- D04B1/00—Weft knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
- D04B1/14—Other fabrics or articles characterised primarily by the use of particular thread materials
- D04B1/16—Other fabrics or articles characterised primarily by the use of particular thread materials synthetic threads
-
- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
- D10B2331/04—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyesters, e.g. polyethylene terephthalate [PET]
-
- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2403/00—Details of fabric structure established in the fabric forming process
- D10B2403/02—Cross-sectional features
- D10B2403/021—Lofty fabric with equidistantly spaced front and back plies, e.g. spacer fabrics
- D10B2403/0213—Lofty fabric with equidistantly spaced front and back plies, e.g. spacer fabrics with apertures, e.g. with one or more mesh fabric plies
-
- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2503/00—Domestic or personal
- D10B2503/06—Bed linen
- D10B2503/062—Fitted bedsheets
-
- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2505/00—Industrial
- D10B2505/08—Upholstery, mattresses
Definitions
- 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.
- 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.
- 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.
- Ventil 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 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 warp-knitted 3D spacer fabrics, as a summer cover which, on account of the greater breathability thereof, produces a better microclimate for the sleeper.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- the inner layer forms a smooth woven fabric layer, for example a layer of non-textured polyester yarn, which may optionally 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, optionally twisted yarn, in particular multifilament yarn, is built up outwardly.
- a smooth woven fabric layer for example a layer of non-textured polyester yarn, which may optionally 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, optionally twisted yarn, in particular multifilament yarn, is built up outwardly.
- the outwardly open recesses may refer to openings or free-areas formed in at least the upper layer, and optionally also in one or more middle layers of the cover fabric.
- Each of the outwardly open recesses may comprise an open cross-section of substantially round or rounded shape, wherein the open-cross-section of the recesses may be defined in a plane of the upper layer, and optionally in one or more planes defined by one or more middle layers.
- Exemplary geometries of the open cross-section may be round, elliptical, or oval.
- each of the outwardly open recesses may extend from the outer face of the mattress cover through the upper layer or through a thickness of the upper layer, for example a thickness measured along or parallel to a surface normal vector of the outer face, adjoining the inner layer of the cover fabric.
- each of the outwardly open recesses may extend from the outer face of the mattress cover through the upper layer and through one or more middle layers of the cover fabric, adjoining the inner layer of the cover fabric.
- each of the outwardly open recesses may be surrounded along a circumference of the respective recess and/or its open cross-section or cross-sectional area, in particular along the whole circumference of the respective recess, by material or fabric of the upper layer, for example by knitted or weft-knitted material or fabric of the upper layer, and optionally by material or fabric, for example knitted or weft-knitted material or fabric, of one or more middle layers of the cover fabric.
- each of the outwardly open recesses in the upper layer may be defined by a knitted fabric or material of the upper layer, which may be knitted or weft-knitted around the respective recess in the upper layer.
- each of the outwardly open recesses in one or more middle layers of the cover fabric may be defined by a knitted fabric or material of the one or more middle layers, which may be knitted or weft-knitted around the respective recess. Accordingly, each of the outwardly open recesses may be surrounded by a plurality of stitches of the upper layer, and optionally of one or more middle layers of the fabric. Accordingly, the outwardly open recesses may have a size or extension in one or more spatial directions, which is larger than a size or extension of a single stitch of the upper layer and/or the one or more middle layers in said one or more spatial directions. For instance, the size of a recess may be at least two times to at least ten times larger than the size of a single stitch of the cover fabric.
- a cross-sectional area of each of the recesses may be substantially identical in the upper layer and in one or more middle layers. Accordingly, a cross-sectional area of each recess may be constant along a direction parallel to a surface normal vector of the outer face, for example along an orthogonal or vertical direction from the upper layer or outer face of the cover fabric towards the inner layer of the cover fabric.
- a cross-sectional area of each recess may be larger in the upper layer compared to the cross-sectional area of the corresponding recess in one or more middle layers of the cover fabric.
- the recesses may extend in a V-shape, U-shape, a cylindrical shape, a conical shape, or a triangular shape from the upper layer of the cover fabric, optionally through one or more middle layers of the cover fabric, and towards or to the inner layer, wherein the cross-section or cross-sectional area of each recess may decrease from the upper layer towards the inner layer of the cover fabric.
- adjacent or neighbouring recesses in the upper layer, and optionally in one or more middle layers may be separated from one another by material or fabric of the upper layer, and optionally of the one or more middle layers.
- the inner layer of the cover fabric may be or form a continuous layer of woven fabric, such as for example knitted or weft-knitted material. Accordingly, the inner layer may form a closed surface of the cover fabric, for example which may not comprise outwardly open recesses.
- the inner layer may be recess-free or a substantially smooth layer of fabric or material, for example knitted or weft-knitted fabric or material.
- each of the recesses may have an open end formed at and/or defined by the outer face and/or the upper layer, and a further end of each recess, which opposes the respective open end in a direction parallel to the surface normal vector and/or along the longitudinal direction of the recess, may be closed.
- the closed end of each recess may be formed and/or defined by the inner layer of the cover fabric.
- 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.
- 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.
- 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.
- the monofilament yarn may be formed of polyester, but other synthetic fibres, such as fibres formed of polyamide, are also possible therefor.
- 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%.
- the inner layer may have a weight portion of cover fabric of from 20% to 30%, in particular from 25% to 30%.
- the cover fabric may have a weight of from 200 g/m 2 to 300 g/m 2 , 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.
- the mattress cover 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.
- 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.
- FIG. 3 is a schematic cross-sectional view through a region of a cover fabric of the mattress cover.
- 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 .
- the surfaces of the cover fabric 5 may also be separated by stitched seams and a welting band may optionally also be provided.
- 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 .
- a plurality of grips 9 for lifting the mattress core 2 , encompassed by the mattress cover 1 are provided on the lateral longitudinal surfaces 7 , just one of said grips or handles 9 being shown by way of example.
- 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 or openings 12 .
- 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.
- 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 or non-textured polyester yarn that is knitted to the upper layer 14 and the middle layer 15 and forms an inner layer 16 .
- 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.
- Each of the outwardly open recesses 12 may extend from the outer face 11 of the mattress cover 1 through the upper layer 14 or through a thickness of the upper layer 14 and through the middle layer 15 , and each recess may adjoin the inner layer 16 of the cover fabric 5 . Further, each recess 12 may be surrounded along a circumference of the respective recess 12 and/or its open cross-section or cross-sectional area by material or fabric of the upper layer 14 and of one or more middle layers 15 of the cover fabric. Accordingly, each of the outwardly open recesses 12 may be surrounded by a plurality of stitches of the upper layer 14 , and the middle layer 15 .
- a cross-sectional area of each of the recesses 12 may be substantially identical in the upper layer 14 and in one or more middle layers 15 . Accordingly, a cross-sectional area of each recess 12 may be constant along a direction parallel to a surface normal vector of the outer face 11 , for example along an orthogonal or vertical direction from the upper layer 14 or outer face 11 of the cover fabric towards the inner layer 16 of the cover fabric 5 . Alternatively, a cross-sectional area of each recess 12 may be larger in the upper layer 14 compared to the cross-sectional area of the corresponding recess 12 in one or more middle layers 15 of the cover fabric 5 .
- the recesses 12 may extend in a V-shape, U-shape, a cylindrical shape, a conical shape, or a triangular shape from the upper layer 14 of the cover fabric 5 , optionally through one or more middle layers 15 of the cover fabric 5 , and towards or to the inner layer 16 , wherein the cross-section or cross-sectional area of each recess 12 may decrease from the upper layer 14 towards the inner layer 16 of the cover fabric.
- the inner layer 16 of the cover fabric 5 may be or form a continuous and/or recess-free layer of woven fabric or material, such as for example knitted or weft-knitted material or fabric. Accordingly, the inner layer 16 may form a closed surface of the cover fabric 5 , for example which may not comprise outwardly open recesses 12 . In other words, the inner layer 16 may be recess-free or a substantially smooth layer of fabric or material, for example knitted or weft-knitted fabric or material. Accordingly, the recesses 12 may only or solely be formed in the upper layer and optionally one or more middle layers 15 .
- 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 .
- 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 .
- 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.
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- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Mattresses And Other Support Structures For Chairs And Beds (AREA)
Abstract
A multilayer weft-knitted fabrics for mattress covers is provided, which comprises a 3D spacer fabric with at least two textile layers. The cover fabric is weft-knitted 3D and comprises openings or recesses at the outer layer thereof.
Description
- This application is a Continuation-in-Part of U.S. application Ser. No. 15/778,825, filed May 24, 2018, which is a National Stage Application of International Application No. PCT/DE2016/100548, filed Nov. 24, 20216, which is based upon and claims the benefit of priority under German Patent Application No. 20 2015 008 053.7, filed Nov. 24, 2015, the entire contents of which are incorporated herein by reference.
- 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 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.
- 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, for example a layer of non-textured polyester yarn, which may optionally 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, optionally twisted yarn, in particular multifilament yarn, is built up outwardly.
- The outwardly open recesses may refer to openings or free-areas formed in at least the upper layer, and optionally also in one or more middle layers of the cover fabric. Each of the outwardly open recesses may comprise an open cross-section of substantially round or rounded shape, wherein the open-cross-section of the recesses may be defined in a plane of the upper layer, and optionally in one or more planes defined by one or more middle layers. Exemplary geometries of the open cross-section may be round, elliptical, or oval.
- Alternatively or additionally, each of the outwardly open recesses may extend from the outer face of the mattress cover through the upper layer or through a thickness of the upper layer, for example a thickness measured along or parallel to a surface normal vector of the outer face, adjoining the inner layer of the cover fabric. Optionally, each of the outwardly open recesses may extend from the outer face of the mattress cover through the upper layer and through one or more middle layers of the cover fabric, adjoining the inner layer of the cover fabric.
- Alternatively or additionally, each of the outwardly open recesses may be surrounded along a circumference of the respective recess and/or its open cross-section or cross-sectional area, in particular along the whole circumference of the respective recess, by material or fabric of the upper layer, for example by knitted or weft-knitted material or fabric of the upper layer, and optionally by material or fabric, for example knitted or weft-knitted material or fabric, of one or more middle layers of the cover fabric. Accordingly, each of the outwardly open recesses in the upper layer may be defined by a knitted fabric or material of the upper layer, which may be knitted or weft-knitted around the respective recess in the upper layer. Alternatively or additionally, each of the outwardly open recesses in one or more middle layers of the cover fabric may be defined by a knitted fabric or material of the one or more middle layers, which may be knitted or weft-knitted around the respective recess. Accordingly, each of the outwardly open recesses may be surrounded by a plurality of stitches of the upper layer, and optionally of one or more middle layers of the fabric. Accordingly, the outwardly open recesses may have a size or extension in one or more spatial directions, which is larger than a size or extension of a single stitch of the upper layer and/or the one or more middle layers in said one or more spatial directions. For instance, the size of a recess may be at least two times to at least ten times larger than the size of a single stitch of the cover fabric.
- In an exemplary embodiment, a cross-sectional area of each of the recesses may be substantially identical in the upper layer and in one or more middle layers. Accordingly, a cross-sectional area of each recess may be constant along a direction parallel to a surface normal vector of the outer face, for example along an orthogonal or vertical direction from the upper layer or outer face of the cover fabric towards the inner layer of the cover fabric.
- Alternatively, a cross-sectional area of each recess may be larger in the upper layer compared to the cross-sectional area of the corresponding recess in one or more middle layers of the cover fabric. For example, the recesses may extend in a V-shape, U-shape, a cylindrical shape, a conical shape, or a triangular shape from the upper layer of the cover fabric, optionally through one or more middle layers of the cover fabric, and towards or to the inner layer, wherein the cross-section or cross-sectional area of each recess may decrease from the upper layer towards the inner layer of the cover fabric.
- Alternatively or additionally, adjacent or neighbouring recesses in the upper layer, and optionally in one or more middle layers, may be separated from one another by material or fabric of the upper layer, and optionally of the one or more middle layers.
- The inner layer of the cover fabric may be or form a continuous layer of woven fabric, such as for example knitted or weft-knitted material. Accordingly, the inner layer may form a closed surface of the cover fabric, for example which may not comprise outwardly open recesses. In other words, the inner layer may be recess-free or a substantially smooth layer of fabric or material, for example knitted or weft-knitted fabric or material. Further, each of the recesses may have an open end formed at and/or defined by the outer face and/or the upper layer, and a further end of each recess, which opposes the respective open end in a direction parallel to the surface normal vector and/or along the longitudinal direction of the recess, may be closed. The closed end of each recess may be formed and/or defined by the inner layer of the cover fabric.
- 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.
- 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.
- 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.
-
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 amattress core 2, the mattress cover 1 forming, for a user sleeping thereon, a first lying surface on anupper 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, lateraltransverse surfaces 6 and longitudinal surfaces 7 also transitioning seamlessly, in the present case, into theupper 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 thetransverse surfaces 6 and longitudinal sides 7. In addition, a plurality of grips 9 for lifting themattress core 2, encompassed by the mattress 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 inFIG. 2 andFIG. 3 , thecover fabric 5 is formed having a weft-knitted3D spacer fabric 10 as far as theouter face 11 thereof, thecover fabric 5 having a honeycombed mesh structure having a regular, delicate arrangement of outwardlyopen recesses 12 oropenings 12. In this case, therecesses 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-knittedspacer fabric 10material projections 13 located between the mutually offset andregular recesses 12 are at least approximately the same. - In the example shown in the figures, the
cover fabric 5 of the mattress cover 1 is designed as a three-layer weft-knitted 3D spacer fabric comprising anupper layer 14 that forms theouter face 11 and is formed of a textured, twisted polyester multifilament yarn; amiddle layer 15 that is made of a coarse polyester multifilament yarn, is knitted to theupper layer 14, jointly forms the weft-knittedspacer fabric 10 and is used as a filling material; and a layer of smooth or non-textured polyester yarn that is knitted to theupper layer 14 and themiddle layer 15 and forms an inner layer 16. - In this case, the
upper layer 14 has a finely knittedstructure 17 on theouter face 11 thereof, which structure provides the surface with a soft feel. - Each of the outwardly
open recesses 12 may extend from theouter face 11 of the mattress cover 1 through theupper layer 14 or through a thickness of theupper layer 14 and through themiddle layer 15, and each recess may adjoin the inner layer 16 of thecover fabric 5. Further, eachrecess 12 may be surrounded along a circumference of therespective recess 12 and/or its open cross-section or cross-sectional area by material or fabric of theupper layer 14 and of one or moremiddle layers 15 of the cover fabric. Accordingly, each of the outwardlyopen recesses 12 may be surrounded by a plurality of stitches of theupper layer 14, and themiddle layer 15. - For example, a cross-sectional area of each of the
recesses 12 may be substantially identical in theupper layer 14 and in one or more middle layers 15. Accordingly, a cross-sectional area of eachrecess 12 may be constant along a direction parallel to a surface normal vector of theouter face 11, for example along an orthogonal or vertical direction from theupper layer 14 orouter face 11 of the cover fabric towards the inner layer 16 of thecover fabric 5. Alternatively, a cross-sectional area of eachrecess 12 may be larger in theupper layer 14 compared to the cross-sectional area of thecorresponding recess 12 in one or moremiddle layers 15 of thecover fabric 5. For example, therecesses 12 may extend in a V-shape, U-shape, a cylindrical shape, a conical shape, or a triangular shape from theupper layer 14 of thecover fabric 5, optionally through one or moremiddle layers 15 of thecover fabric 5, and towards or to the inner layer 16, wherein the cross-section or cross-sectional area of eachrecess 12 may decrease from theupper layer 14 towards the inner layer 16 of the cover fabric. - Adjacent or neighbouring
recesses 12 in theupper layer 14, and optionally in one or moremiddle layers 15, may be separated from one another by material or fabric of theupper layer 14, and optionally of the one or more middle layers 15. - The inner layer 16 of the
cover fabric 5 may be or form a continuous and/or recess-free layer of woven fabric or material, such as for example knitted or weft-knitted material or fabric. Accordingly, the inner layer 16 may form a closed surface of thecover fabric 5, for example which may not comprise outwardly open recesses 12. In other words, the inner layer 16 may be recess-free or a substantially smooth layer of fabric or material, for example knitted or weft-knitted fabric or material. Accordingly, therecesses 12 may only or solely be formed in the upper layer and optionally one or more middle layers 15. - 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 thecover fabric 5, in order make use, as far as possible, of the microclimatic advantages of the weft-knittedspacer 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 themiddle layer 15 until adjacent to the lower layer 16 such that, as a result of therecesses 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 themiddle layer 14. - 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.
Claims (14)
1. Mattress cover comprising:
a cover fabric that forms an upper face and a lower face that are each dimensioned as a lying surface for a user,
wherein the cover fabric is formed having a weft-knitted 3D spacer fabric at least on an outer face thereof and comprises a honeycombed mesh structure having outwardly open recesses on the outer face thereof,
wherein the cover fabric is formed in at least two layers from a weft-knitted 3D spacer fabric, having an upper layer that consists of textured yarn, which forms the outer face, and a layer of polyester yarn which forms an inner layer of the cover fabric; and
wherein the recesses are only formed in the upper layer.
2. The mattress cover according to claim 1 ,
wherein 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.
3. The mattress cover according to claim 2 ,
wherein the monofilament yarn of the middle layer is formed of polyester or polyamide.
4. The mattress cover according to claim 1 ,
wherein the recesses extend at least over a thickness of the upper layer or over a thickness of the upper layer and over a thickness of the middle layer.
5. The mattress cover according to claim 1 ,
wherein the upper layer has a weight portion of cover fabric ranging from 50% to 70%.
6. The mattress cover according to claim 5 ,
wherein the upper layer has a weight portion of cover fabric ranging from 55% to 60%.
7. The mattress cover according to claim 1 ,
wherein the inner layer has a weight portion of cover fabric ranging from 20% to 30%.
8. The mattress cover according to claim 7 ,
wherein the inner layer has a weight portion of cover fabric ranging from 25% to 30%.
9. The mattress cover according to claim 1 ,
wherein the middle layer has a weight portion of cover fabric ranging from 10% to 20%.
10. The mattress cover according to claim 9 ,
wherein the middle layer has a weight portion of cover fabric ranging from 15% to 20%.
11. The mattress cover according to claim 1 ,
wherein the cover fabric has a weight ranging from 250 g/m2 to 300 g/m2.
12. The mattress cover according to claim 1 ,
wherein the cover fabric is the same on all faces.
13. The mattress cover according to claim 1 ,
wherein said cover comprises a fastener that is peripheral at least in part and that is openable in order to insert or remove a mattress core.
14. The mattress cover according to claim 13 , wherein the fastener is a zip fastener.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US17/991,496 US20230160113A1 (en) | 2015-11-24 | 2022-11-21 | Multilayer weft-knitted fabrics for mattress covers |
Applications Claiming Priority (5)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE202015008053.7U DE202015008053U1 (en) | 2015-11-24 | 2015-11-24 | mattress cover |
DE202015008053.7 | 2015-11-24 | ||
PCT/DE2016/100548 WO2017088857A1 (en) | 2015-11-24 | 2016-11-24 | Mattress cover |
US201815778825A | 2018-05-24 | 2018-05-24 | |
US17/991,496 US20230160113A1 (en) | 2015-11-24 | 2022-11-21 | Multilayer weft-knitted fabrics for mattress covers |
Related Parent Applications (2)
Application Number | Title | Priority Date | Filing Date |
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PCT/DE2016/100548 Continuation-In-Part WO2017088857A1 (en) | 2015-11-24 | 2016-11-24 | Mattress cover |
US15/778,825 Continuation-In-Part US20180344049A1 (en) | 2015-11-24 | 2016-11-24 | Mattress cover |
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US20230160113A1 true US20230160113A1 (en) | 2023-05-25 |
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US17/991,496 Pending US20230160113A1 (en) | 2015-11-24 | 2022-11-21 | Multilayer weft-knitted fabrics for mattress covers |
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Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
USD1005012S1 (en) * | 2023-03-02 | 2023-11-21 | Rifka S. Schwartz | Mattress cover |
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2022
- 2022-11-21 US US17/991,496 patent/US20230160113A1/en active Pending
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
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USD1005012S1 (en) * | 2023-03-02 | 2023-11-21 | Rifka S. Schwartz | Mattress cover |
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