WO2021011180A1

WO2021011180A1 - Mattress topper with integrally connected layers of varying firmness

Info

Publication number: WO2021011180A1
Application number: PCT/US2020/040167
Authority: WO
Inventors: Michael Loomis
Original assignee: Corsicana Bedding, LLC
Priority date: 2019-06-28
Filing date: 2020-06-29
Publication date: 2021-01-21
Also published as: US20200405069A1

Abstract

A mattress topper (20) includes a first layer (21), a second layer (22), and a third layer (23). The first layer (21) and third layer (23) are made of a foam material. The second layer (22) is sandwiched between the first layer (21) and the third layer (23). The first layer (21) and the third layer (23) are connected directly to each other.

Description

THE UNITED STATES PATENT AND TRADEMARK OFFICE

MATTRESS TOPPER WITH INTEGRALLY CONNECTED LAYERS OF VARYING

FIRMNESS

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This patent application claims the benefit of pending nonprovisional patent application 16/459,267 filed July 1, 2019 and expired provisional patent application 62/868,546 filed June 28, 2018, which is incorporated herein by reference in its entirety.

TECHNICAL FIELD

[0002] This disclosure relates generally to mattress toppers and more particularly to mattress toppers that contain layers of varying firmness.

BACKGROUND

[0003] A mattress topper lies on top of a mattress and may be used to change the firmness of the mattress. Often, mattress toppers are used to make a bed feel firmer or softer to a person who is laying upon it. One problem with mattress toppers is that they do not provide varying levels of firmness. A person may want a softer or more flexible feeling at one time, and at another time, prefer a firmer feel. Another problem is that mattress toppers do not provide a smooth and consistent edge. A mattress topper often makes a bed look bulky and does not provide a smooth design aesthetic that blends easily into the shape of a bed. Accordingly, what is needed is mattress topper design with integral layer of varying firmness.

SUMMARY

[0004] In one embodiment, a mattress topper is provided. The mattress topper includes a first layer made of a first foam material, a second layer made of a compressible material, and a third layer of a second foam material. The first layer and the third layer overlie the second layer of the second material such that the second layer is sandwiched between the first layer and the third layer. The first layer and the third layer are connected directly to each other. BRIEF DESCRIPTION OF THE DRAWINGS

[0005] In the following description, for purposes of explanation, numerous specific details are set forth in order to provide an understanding of the variations in implementing the disclosed technology. However, the instant disclosure may take many different forms and should not be construed as limited to the examples set forth herein. Where practical, like numbers refer to like elements throughout.

[0006] Fig. 1 is a perspective view of a support surface and a mattress topper with one side partially cutaway to display the layers of the mattress topper.

[0007] Fig. 2 is a partial sectional view taken along line 2-2 of a middle portion of the support surface and mattress topper of Fig. 1.

[0008] Fig. 3 is a partial sectional view taken along line 2-2 of an end portion of the support surface and mattress topper of Fig. 1.

DETAILED DESCRIPTION

[0009] Referring to Fig. 1, one embodiment of a support surface 10 and mattress topper 20 are shown for illustrative purposes. Support surface 10 in one example is a mattress 12. In another example, support surface 10 may be another surface upon which a user may want to lay down or sit. For example, support surface 10 may be a table, a cot, a board, a box spring, a couch, etc.

[0010] Mattress topper 20 in one example includes a first layer 21, a second layer 22, a third layer 23, and a cover 24. In one embodiment, first layer 21, second layer 22, and third layer 23 are made of material having varying firmness. In one example, first layer 21 may comprise a layer of foam material having a first degree of firmness. Third layer 23 may comprises a layer of foam material having a different degree of firmness that the first layer 21. For example, the first layer 21 may be firmer than the third layer 23. Accordingly, a user could position first layer 21 such that it is facing upward from support surface 10 and could lay upon the first layer 21 for a softer feel. The user could flip the topper 20 over such that the third layer 23 is facing upward from the support surface 10 and could lay upon it for a firmer feel. In one embodiment, first layer 21, second layer 22, and third layer 23 are shaped and dimensioned such that they (and topper 20) are the same size as a mattress. For instance, they could be the size of twin, double, queen, or king-sized beds.

[0011] In one embodiment, mattress topper 20 has two opposing sides 25 and two opposing ends 26. The opposing sides 25 and opposing ends 26 are spaced apart from each other such that they form a perimeter 27. As such, first layer 21, second layer 22, and third layer 23 also have opposing sides 25 and opposing ends 26 corresponding to each other.

[0012] Second layer 22 in one example comprises an intermediate layer that provides support against first layer 21 and third layer 23 when a user is laying upon topper 20. In one example, second layer 22 may comprise a layer of pocketed coils. In another example, second layer 22 may comprise another layer of foam material. In another example, second layer 22 may comprise another type of material that could provide support against first layer 21 and third layer 23. Examples include, but are not limited to gels, rubbers, plastics, liquids, and the like.

[0013] Referring further to Fig. 1, cover 24 in one example comprises a layer of material that holds topper 20 within it. Cover 24 in one example also may include a flap that may be used to secure topper 20 to mattress, as will be further described herein. Such a flap may include a layer of elastic material that can secure topper 20 to a mattress in the manner of a bed sheet.

[0014] Referring to Fig. 2, in one embodiment, first layer 21 and third layer 23 are equal or substantially equal in thickness and second layer 22 has a thickness that is different than first layer 21 and second layer 23. For instance, first layer 21 and third layer 23 may be thicker than second layer 22. In one example, first layer 21 and third layer 23 may be one (1) inch thick and second layer 22 may be three quarters (¾) of an inch thick. It should be noted that these dimensions are provided for illustrative purposes only and alternative dimensions are also possible without departing from the scope of this disclosure. For example, first layer 21 and third layer 23 could be two (2) inches thick and second layer 22 could be one and a half (1 ½) inches thick, or first layer 21 and third layer 23 could be one half (½) and inch thick and second layer could be three eights (3/8) of an inch thick. In another example, first layer 21, second layer 22, and third layer 23 could be of the same thickness. In a further example, first layer 21, second layer 22, and third layer 23 could all have distinct levels of thickness.

[0015] In one embodiment first layer 21 and third layer 23 are made of foam. The foam used to make first layer and second layer may be memory foam, conventional foam, latex, or one or more combinations thereof. In one embodiment second layer 22 may be a pocket coil pad having a top surface 31 and a bottom surface 32. In one example, there a plurality of pocketed coils 33 which extend from the top surface 31 and the bottom surface 32. The pocketed coils 33 in one example include a pocket 34 made of fabric and a compressible coil 35 within the pocket 34. The coils 35 in one example are three quarters (¾) of an inch high. The pocketed coils 33 are joined together by a fabric covering that holds pocketed coils 33 together as a unitary structure.

[0016] Referring to Fig. 3, in one embodiment, second layer 22 is sandwiched between first layer 21 and third layer 23. First layer 21 and third layer 23 are secured together at opposing sides 25 and opposing ends 26 such that first layer 21 and third layer 23 are pinched together along perimeter 27. First layer 21 and third layer 23 may be secured together through the use of an adhesive, such as glue. In another example, first layer 21 and third layer 23 may be secured together through alternative means, such as stitching or thermal bonding. The pinching together of first layer 21 and third layer 23 provides the topper 20 with a smooth and consistent edge that enhances the design aesthetic of the topper 20.

[0017] Referring further to Fig. 3, in one example, cover 24 may include a pocket 28 and a flap 29. The pocket 28 in one example encloses first layer 21, second layer 22, and third layer 23 within it. The flap 29 in one example is a fabric material that is attached to pocket 28 and extends downward toward mattress 12. The flap 29 may be tucked under mattress to secure topper 20 to mattress 10. In one example, the flap 29 may be made at least partially from a stretchable material such as elastic. Flap 29 may be formed integrally with pocket 28 or connected thereto, such as with glue or an adhesive. Flap 29 may extend along perimeter 27 of topper 20.

[0018] While the disclosure has been provided in connection with what is presently considered to be the most practical and preferred embodiments of the mattress topper described herein, it is to be understood that the disclosure is not to be limited to the disclosed embodiments, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.

Claims

1. A mattress topper, comprising:

a first layer made of a first foam material;

a second layer made of a compressible material;

a third layer of a second foam material; wherein the first layer of the first foam material and the third layer of the second foam material overlie the second layer such that the second layer is sandwiched between the first layer and the third layer; and further wherein the first layer and the third layer are connected directly to each other.

2. The mattress topper of claim 1, wherein the first material and the third material are compressible foam.

3. The mattress topper of claim 2, wherein the first material and the third material have different levels of firmness.

4. The mattress topper of claim 3, wherein the second layer comprises a pocketed coil layer.

5. The mattress topper of claim 1, wherein the first layer and the third layer each have opposing sides and opposing edges that define a perimeter.

6. The mattress topper of claim 5, wherein the first layer and the third layer are connected together continuously along the perimeter.

7. The mattress topper of claim 6, wherein the first layer and the third layer are glued together.

8. The mattress topper of claim 7, wherein the first layer and the third layer are pinched together around the second layer.

9. The mattress topper of claim 1, wherein the first layer and the third layer are thicker than the second layer.

10. The mattress topper of claim 1, wherein the first layer and the third layer are each at least one (1) inch thick.

11. The mattress topper of claim 10, wherein the second layer is at least three quarters of an inch thick.

12. The mattress topper of claim 10, wherein the second layer is made of a plurality of pocketed coils comprising a fabric pocket and a compressible coil positioned therein.

13. The mattress topper of claim 10, further comprising a cover that surrounds the mattress topper.

14. The mattress topper of claim 13, wherein the cover comprises a pocket and a flap connected to the pocket.

15. The mattress topper of claim 14, wherein the flap is adapted to be secured to a mattress.