Mattress covers with secret fold-over and method for manufacturing the same

Description

TECHNICAL FIELD

[0001] The present disclosure generally relates to mattress covers and their methods of manufacture. More specifically, embodiments relate to mattress covers that may be used in households, hotels, motels, and healthcare facilities, and their methods of manufacture.BACKGROUND

[0002] A conventional bed includes a box spring or bottom mattress or platform and a top mattress. Top mattresses are relatively heavy items. The weight of a mattress varies as a function of the coil core, the gauge of the coil, and the type of material or foam material used. An average king size mattress weighs between 38,6 and 52,2 kilograms ( 85 and 115 pounds). High end king size mattresses with latex or memory foam can weigh as much as 136 kilograms (300 pounds).

[0003] Hotel and motel chains as well as healthcare facilities which include hospitals, nursing homes and extended care facilities (hereinafter "commercial facilities") are known to only use flat sheets in their facilities due to the lower cost of flat sheets relative to fitted sheets and the desire to maintain fewer items in their respective inventories. As such, in order to properly make the beds in such facilities with flat sheets, housekeeping personnel need to lift the top mattress, which can be quite heavy, as discussed above. More particularly, in such facilities beds are made with a top sheet and a bottom sheet and a blanket. Both the top sheet and the bottom sheets are flat sheets.

[0004] In order to properly make the bed, the top and bottom sheets are tucked in between the top mattress and the box spring. More specifically, the bottom sheet is placed on the bed so that an equal amount of the sheet hangs off each side of the bed and an equal amount of the sheet hangs off the head and foot regions of the bed. The excess is tucked in at the head and foot regions of the bed to form so called "hospital corners." Next, the excess portions of the bottom sheet are tucked in next between the mattress and the box spring. The top sheet is then placed on top of the bottom sheet and placed and tucked in the same manner as the bottom sheet with hospital style corners except the head region is left open. In other words, only the foot and side portions of the top sheet are tucked between the mattress and the box spring. Next, a blanket is placed on the bed and may be tucked in the same manner as the top sheet.

[0005] In order to tuck the top and bottom sheets between the mattress and the box spring, the top mattress must normally be lifted. As mentioned above, mattresses can weigh up to 136 kilograms (300 pounds). In order to make a bed, a housekeeping employee may need to lift a mattress up to ten (10) times per bed; four (4) times for the bottom sheet and three (3) times for the top sheet and the blanket. Assuming that each housekeeping employee in a hotel, motel, or healthcare facility makes at least 20-30 beds in a single shift, each housekeeping employee would typically lift a mattress at least 150-200 times per shift. Since bed making is a daily chore, housekeeping employees probably lift mattresses 150-200 times per shift on a daily basis.

[0006] Such sustained and repetitive lifting leads to employees developing back problems, resulting in employees missing work or, in severe cases, being placed on disability. Measures have been taken to mitigate such health problems. For example, simply using fitted sheets for the lower sheet reduces the number of times the mattress is to be lifted by 40%. However, fitted sheets do not provide the "hospital corners" in the lower bed sheets that hospitals are known for. Moreover, even using fitted sheets for the bottom sheet still requires a housekeeping employee to lift mattresses at least 90-160 times per day using the example above.

[0007] The use of fitted sheets is not without its drawbacks. For example, fitted sheets cost more than flat sheets. Also, frequent washing of sheets in commercial facilities tends to wear out the elastic in fitted sheets. As such, fitted sheets used in such facilities need to be replaced in applications in commercial facilities more frequently than straight sheets.

[0008] Thus, there is a need for further minimizing the need for housekeeping employees to lift mattresses while still making the bed look aesthetically neat.

[0009] US20050071924 discloses improved bedding, more particularly institutional and hotel top and / or bottom sheets and blankets having a specially contoured foot section that provides for faster changing, ease of tucking under a mattress, and less pressure on the feet of the occupant (sleeper) or bed-ridden patient. The best mode example comprises a bedding sheet or blanket having the foot-end, or / and the head end corners cut away, and those edged secured with binding tape, selvage edge sewing or the like to prevent raveling or tearing at the juncture of the cuts. For a top sheet or blanket, only the foot corners are cut away, and for a bottom sheet both the foot and head ends are cut away. The resulting bedding can be tucked without extra, folded-over bedding in the corner tuck.

[0010] GB2047084 discloses a duvet, eiderdown or comforter or any similar quilt intended for location on a bed has located on one side and substantially parallel to but spaced from at least one edge a tuck in the cover thereof to which is attached or attachable thereto a flap whereby the duvet may be restrained from movement relative to the bed. For instance, the flap may be tucked between the mattress and the bed frame. The tuck may be inwards of the cover, or outwardly thereof. Other examples of known mattress covers are disclosed in US2007 / 240262A1, US2007 / 266495A1, US6502258B1 and US3144666A.SUMMARY

[0011] Briefly, the present invention relates to a mattress cover that may advantageously provide the benefits of being modular in terms of size and shape, easily removable and replaceable, comfortable and secure, all while maintaining an aesthetically, orderly, or neat and trim look.

[0012] More specifically, the present invention relates to a system and method for facilitating making beds of all sizes with one or more mattress covers by minimizing lifting of the mattress so that mattress cover can be tucked between the upper mattress and the box spring or platform without lifting the top mattress as many times. As such, flat sheets and blankets made in accordance with the present invention can be tucked between a mattress and box spring or platform virtually effortlessly without the need to lift the top mattress as many times. The present invention thus increases the efficiency of the housekeeping staff leaving more time for the housekeeping staff to attend to the rest of the room.

[0013] The present invention provides a mattress cover as defined in claim 1 and a method of making a mattress cover as defined in claim 13. Preferred features of the invention are set out in the dependent claims.

[0014] Various objects, features, aspects and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.BRIEF DESCRIPTION OF THE DRAWINGS

[0015] It is to be noted, however, that the drawings illustrate only example embodiments of the invention and is therefore not to be considered limiting of its scope. FIG. 1 illustrates a set up including a conventional mattress carried by a platform bed, and a flat sheet spread on top of the mattress, according to the teachings of prior art. FIG. 2 illustrates a schematic representation of an exemplary mattress cover in accordance with an embodiment of the present disclosure. DETAILED DESCRIPTION

[0016] The methods and mattress covers of the present disclosure can now be described more fully hereinafter with reference to the accompanying drawings in which embodiments are shown.

[0017] The term "mattress cover" as used throughout this disclosure means a flat sheet, duvet, top sheet, mock duvet, duvet cover or any other means that may be used to cover a mattress. More specifically, embodiments disclosed relate to mattress covers that may be used in households, hotels, motels, and healthcare facilities, and their methods of manufacture.

[0018] Turning now to the figures, FIG. 1 is a prior art set up including a conventional mattress 15 carried by a platform bed 35, including a flat sheet 10 spread on top of the mattress, according to the teachings of prior art. The expression "mattress" referred to in the instant application refers to a fabric case filled with fillers including but not limited to one or more combinations of cotton, hair, feather, down, foam, rubber, springs, and the like. All embodiments claimed and described herein with regards to "mattress" are understood to include "mattress" used as a bed by itself, on a bedstead, water beds, air beds, "seat cushions" used on a sofa, couch, love seat, chair and the like, and tuffets.

[0019] FIG. 2 illustrates a mattress cover 100, according to one example embodiment. The mattress cover 100 includes a fabric substrate 102 having a top surface, a bottom surface, a head portion 122, a foot portion 124, a length 110, and a width 112. The mattress cover 100 also includes a secret tuck portion 104 attached to the foot portion 124 on the bottom surface of the fabric substrate 102. The secret tuck portion 104 has a length 114 and a width 116. According to the invention, the width 116 of the secret tuck portion 104 is less than the width 112 of the fabric substrate 102. The length 114 of the secret tuck portion 104 may be significantly less than the length 110 of the fabric substrate 102. According to the invention the secret tuck portion 104 is stitched or sewn to the foot portion 124 on the bottom surface of the fabric substrate 102.

[0020] In one embodiment, the width of the secret tuck portion 104 is equal to the width of a mattress on which the mattress cover 100 is used. For example, the mattress may be a twin, twin XL, full, queen, king, California king, or custom sized mattress. According to the invention the secret tuck portion 104 is attached to the foot portion 124 on the bottom surface (along dotted line 106) of the fabric substrate 102 at about 60-90% of the length 114 of the secret tuck portion 104, or preferably about 70-80% of the length 114 of the secret tuck portion 104. The secret tuck portion 104 can be made of the same material as the fabric substrate 102 or of a different material. For example, the secret tuck portion 104 may include a sheeting fabric, while the fabric substrate 102 can be a multilayered structure comprising two or more layers of a fabric. The secret tuck portion 104 may be foldable towards the bottom surface and concealed when not in use or when not tucked under the mattress. In one embodiment, the mattress cover 100 may include one or more layers of a second fabric.

[0021] According to the invention, at least a portion of the secret tuck portion 104 of the mattress cover 100 is configured to be resilient and extendible along a depth of the mattress such that the mattress cover is releasably secured to the mattress. For example, at least one resilient member may be attached along one or more edges of the secret tuck portion 104 to provide for such a feature. The at least one resilient member can be sandwiched between two layers of a fabric in order to conceal the resilient member. The at least one resilient member may be attached in a vertical direction along the depth of the mattress or at an angle relative to the vertical direction.

[0022] Turning now to Fig. 2, a fabric weight of the fabric substrate 102, the second fabric, and / or the secret tuck portion 104 can be in the range of about 10 gsm to 1000 gsm. The fabric substrate 102, the second fabric, and / or the secret tuck portion 104 may include at least one of cotton, polyester, nylon, and rayon yarns in either warp and / or weft direction. For example, the fabric substrate 102, the second fabric, and / or the secret tuck portion 104 may include 100% polyester yarns. The fabric substrate 102, the second fabric, and / or the secret tuck portion 104 may include at least one of a woven, knitted, nonwoven, and extruded base. In one embodiment, the fabric substrate 102, the second fabric, and / or the secret tuck portion 104 may have a patterned or textured surface so as to improve the aesthetic appearance and / or tactile feel of the mattress cover. The yarn density of the warp and weft yarns can be in the range of about 25 to 500 denier.

[0023] In one example embodiment, a portion of the head portion 122 is folded backwards towards the bottom surface of the mattress cover 100, and seams 118 are provided along an outer edge of the side portions to retain the head portion in a folded position. Additional seaming 120 may be provided along the folded portion and across the width of the mattress cover 100 such that the seam 120 would only appear on the bottom surface of the fabric substrate.

[0024] In one embodiment, at least a portion of the side portions may be configured to be resilient and extendible along a depth of a mattress such that the mattress cover is releasably secured to the mattress. For example, at least one resilient member may be configured to be sandwiched between two layers of a fabric, or the seam portion may be made resilient. In another embodiment, at least one resilient member is attached along corners that conform with corners of the mattress. In one embodiment, at least one resilient member is attached in a vertical direction along the depth of the mattress or at an angle relative to the vertical direction. In one embodiment, the mattress cover may also include one or more layers of fabric stiffeners, resilient material and the like in at least some portions of the sheets. The expression "resilient" referred to in the instant application refers to a property of a material that enables it to return to its original shape after being pulled or stretched. The expression "resilient member" referred to in the instant application may include elastomeric materials that are inherently resilient by nature, such as elastic and also materials that can be pulled or tugged and released by means of ropes, cords, drawstrings configured therein to achieve desired tensioning or release effect. The expression "resilient member" may also include fabric configured with resilience by techniques such as but not limited to smocking and shirring. "Resilient member" in the instant application can take any form including but not limited to bands, tapes, strips, threads, and the like, which may be produced using Lycra ®< , Spandex ®< , and the likes, an elastomer, polyurethane, or any other polymeric material. The expressions "sew" and "stitch" may be used interchangeably to imply fastening or joining by stitching or other forms of bonding, as known in the art and may be a manual process or may involve use of machines.

[0025] Another example embodiment is a method of making a mattress cover including providing a fabric substrate 102 having a top surface, a bottom surface, a head portion 122, a foot portion 124, a first length 110, and a first width 112. The method further includes attaching a secret tuck portion 104 to the foot portion 124 on the bottom surface of the fabric substrate 102, the secret tuck portion having a second length 114 and a second width 116, wherein the second width 116 is less than the first width 112. The second length 114 may be significantly less than the first length 110. According to the invention, the secret tuck portion 104 is stitched or sewn to the foot portion 124 on the bottom surface of the fabric substrate 102.

[0026] In one embodiment, the width of the secret tuck portion 104 is equal to the width of a mattress on which the mattress cover 100 is used. For example, the mattress may be a twin, twin XL, full, queen, king, California king, or custom sized mattress. The secret tuck portion 104 can be attached to the foot portion 124 on the bottom surface (along dotted line 106) of the fabric substrate 102 at about 60-90% of the length 114 of the secret tuck portion 104, or preferably about 70-80% of the length 114 of the secret tuck portion 104. The secret tuck portion 104 can be made of the same material as the fabric substrate 102 or of a different material. For example, the secret tuck portion 104 may include a sheeting fabric, while the fabric substrate 102 can be a multilayered structure comprising two or more layers of a fabric. The secret tuck portion 104 may be foldable towards the bottom surface and concealed when not in use or when not tucked under the mattress. In one embodiment, the mattress cover 100 may include one or more layers of a second fabric.

[0027] According to the invention, at least a portion of the side portions of the mattress cover 100 is configured to be resilient and extendible along a depth of a mattress such that the mattress cover is releasably secured to the mattress. The at least one resilient member is further configured to be sandwiched between two layers of a fabric. The at least one resilient member, for example, may be attached along corners that conform with corners of the mattress. The at least one resilient member may be attached in a vertical direction along the depth of the mattress or at an angle relative to the vertical direction.

[0028] Turning now to Fig. 2, a fabric weight of the fabric substrate 102, the second fabric, and / or the secret tuck portion 104 can be in the range of about 10 gsm to 1000 gsm. The fabric substrate 102, the second fabric, and / or the secret tuck portion 104 may include at least one of cotton, polyester, nylon, and rayon yarns in either warp or weft direction. The fabric substrate 102, the second fabric, and / or the secret tuck portion 104 may include 100% polyester yarns. The fabric substrate 102, the second fabric, and / or the secret tuck portion 104 may include at least one of a woven, knitted, nonwoven, and extruded base. The fabric substrate 102, the second fabric, and / or the secret tuck portion 104 may have a patterned or textured surface. The yarn density of the warp and weft yarns can be in the range of about 25 to 500 denier.

[0029] In one embodiment, a portion of the head portion 122 is folded backwards towards the bottom surface of the mattress cover 100, and seams 118 are provided along an outer edge of the side portions to retain the head portion in a folded position. Additional seaming 120 may be provided along the folded portion and across the width of the mattress cover 100 such that the seam 120 would only appear on the bottom surface of the fabric substrate.

[0030] The present disclosure provides various embodiments to achieve resilience and meet the intended objects of the disclosure. In an embodiment, at least a portion of the side surfaces can be configured to be resilient. For instance, at least a portion of the side surfaces can be made of stretchable material such as Lycra ®< or Spandex ®< and the like. In an embodiment, corners of the side surfaces that conform to the four corners of the mattress on which the contour sheet may be spread can be made of such resilient material. Alternatively, spaced apart portions of the side surfaces can be made of such resilient material. In another embodiment, the side surfaces can be monolithic and made entirely of such resilient material.

[0031] Furthermore, this invention is applicable not only to fluid-cell mattress but any type of mattress with a filler material. It is also possible to use a mattress main body using metal springs such as coil springs or spring steel linear materials instead of air spring of the cells, or a mattress main body whose entirety is formed of a polymeric elastomer like a polyurethane foam.

[0032] It will be appreciated by a person skilled in the art that although the mattress cover 100 has been described with respect to a mattress, the mattress cover 100 may alternatively be used on a box spring. Further, the mattress cover 100 may be provided in different sizes and shapes for use with mattresses, box springs, couch cushions, chair cushions, pillows and duvets, for example, or any stuffed or filled article (whether stuffed or filled by natural or man-made materials).

[0033] The mattress cover disclosed here can take the form of any of the following: bed skirts, contour sheets or fitted sheets that cover the mattress, top sheets or flat sheets, blankets or duvets and pillow shams among other items. The mattress cover not only provides comfort, but also provide the advantage of the washed regularly instead of frequently washing the mattresses, thereby providing equivalent effect of cleanliness and hygiene, which in turn increases user convenience and reduces associated costs and resources on a recurring basis. Additionally, these items also provide an appealing bed presentation especially with appropriate color combinations and designs. However, an important aspect from the point of view of aesthetic appeal, comfort and safety is how well the bedding items are laid and avert accidents due to overhanging portions that may cause tripping.

[0034] The mattresses covers in the present disclosure can be customized to fit any standard mattress size such as King, Queen, Twin, Full, and the like. The mattress cover disclosed in the above embodiments is a critical and basic item in bedding sets that is laid over the mattress and is intended to snugly fit the mattress. Such covers can also find application for seat cushions in sofas, couches, love seats, and tuffets. With varying depths of mattresses and seat cushions available in the market today, there is a need to ensure that mattress covers are standardized for a particular size and are yet able to cater to the varying depths of mattresses or cushions available for each size.

[0035] The Specification, which includes the Summary, Brief Description of the Drawings and the Detailed Description, and the appended Claims refer to particular features (including process or method steps) of the disclosure. Those of skill in the art understand that the disclosure is not limited to or by the description of embodiments given in the Specification.

[0036] Those of skill in the art also understand that the terminology used for describing particular embodiments does not limit the scope or breadth of the disclosure. In interpreting the Specification and appended Claims, all terms should be interpreted in the broadest possible manner consistent with the context of each term. All technical and scientific terms used in the Specification and appended Claims have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs unless defined otherwise.

[0037] As used in the Specification and appended Claims, the singular forms "a," "an," and "the" include plural references unless the context clearly indicates otherwise. The verb "comprises" and its conjugated forms should be interpreted as referring to elements, components or steps in a non-exclusive manner. The verb "operatively connecting" and its conjugated forms means to complete any type of required junction, including electrical, mechanical or fluid, to form a connection between two or more previously non-joined objects. If a first component is operatively connected to a second component, the connection can occur either directly or through a common connector. "Optionally" and its various forms means that the subsequently described event or circumstance may or may not occur.

Claims

1. A mattress cover (100) comprising: a fabric substrate (102) having a top surface, a bottom surface, a head portion (122), a foot portion (124), a first length (110), and a first width (112); and a secret tuck portion (104) attached to the foot portion (124) on the bottom surface of the fabric substrate (102), wherein the secret tuck portion (104) is stitched or sewn to the foot portion (124) on the bottom surface of the fabric substrate (102), the secret tuck portion (104) having a second length (114) and a second width (116), wherein the second width (116) is less than the first width (112), wherein at least a portion of the secret tuck portion (104) is configured to be resilient and extendible along a depth of a mattress such that the mattress cover (100) is releasably securable to the mattress, wherein the secret tuck portion (104) is attached to the foot portion (124) on the bottom surface of the fabric substrate (102) at about 60-90% of the second length (114), and wherein the secret tuck portion (104) is foldable towards the bottom surface and concealed when not in use or when not tucked under the mattress2. The mattress cover according to claim 1, wherein the second length is significantly less than the first length.

3. The mattress cover according to any of the preceding claims, wherein the secret tuck portion is attached to the foot portion on the bottom surface of the fabric substrate using a hook and loop type fastener or Velcro®.

4. The mattress cover according to any preceding claim, wherein the secret tuck portion is attached to the foot portion on the bottom surface of the fabric substrate at about 70-80% of the second length.

5. The mattress cover according to any of the preceding claims, wherein the secret tuck portion is made of the same material as the fabric substrate or of a different material.

6. The mattress cover according to any of the preceding claims, further comprising one or more layers of a second fabric.

7. The mattress cover according to claim 6, wherein a fabric weight of the fabric substrate or the second fabric is in the range of about 10 gsm to 1000 gsm.

8. The mattress cover according to claim 6, wherein the fabric substrate or the second fabric comprises at least one of cotton, polyester, nylon, and rayon yarns in either warp or weft direction.

9. The mattress cover according to claim 6, wherein the fabric substrate or the second fabric comprises 100% polyester yarns.

10. The mattress cover according to claim 6, wherein the fabric substrate or the second fabric comprise at least one of a woven, knitted, nonwoven, and extruded base.

11. The mattress cover according to claim 6, wherein the fabric substrate or the second fabric has a patterned or textured surface.

12. The mattress cover according to claim 9, wherein the yarn density of the warp and weft is the range of about 25 to 500 denier.

13. A method of making a mattress cover (100) comprising: providing a fabric substrate (102) having a top surface, a bottom surface, a head portion (122), a foot portion (124), a first length (110), and a first width (112); attaching a secret tuck portion (104) to the foot portion (124) on the bottom surface of the fabric substrate (102), stitched or sewn to the foot portion (124) on the bottom surface of the fabric substrate (102), the secret tuck portion (104) having a second length (114) and a second width (116), wherein the secret tuck portion (104) is attached to the foot portion (124) on the bottom surface of the fabric substrate (102) at about 60-90% of the second length (114); wherein the second width (116) is less than the first width (112); wherein at least a portion of the secret tuck portion (104) is configured to be resilient and extendible along a depth of a mattress such that the mattress cover (100) is releasably securable to the mattress; and wherein the secret tuck portion (104) is foldable towards the bottom surface and concealed when not in use or when not tucked under the mattress.