Pillowtop mattress including foam encased topper

Abstract

Pillowtop mattresses include a pillowtop portion including a foam encased topper. The foam encased topper includes a center foam encased by a foam rail about a perimeter of the center foam. The center foam has an indention force deflection value less than the foam rail. The pillowtop mattresses further include a fabric top panel assembly, which can be smooth or quilted, that includes a flange extending about a perimeter thereof, wherein the flange can be stapled under tension to the foam rail of the foam encased topper during assembly of the pillowtop mattress.

Description

CROSS REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of U.S. Application No. 63 / 675,821, filed on Jul. 26, 2024.BACKGROUND

[0002] The present disclosure generally relates to a pillowtop mattress including a foam encased topper and processes of manufacture.

[0003] In the manufacture of pillowtop mattresses, a top panel that includes a foam or cushion material is secured above a separate foam or cushion material in the pillowtop. Traditionally the top panel is secured to the pillowtop material via adhesive. The foam or cushion material in the pillowtop typically has a length and width dimension that approximates the length and width dimensions of the underlying mattress. A mattress border fabric is then attached to the fabric top panel overlaying the foam of cushion material and forming a pillowtop gusset. Further, the upper panels and pillowtop gussets of mattresses generally must be sewn or attached to the mattress border by a tape edge, which is applied along the mating edges or seams therebetween by a tape edge applicator.

[0004] As noted above, the foam or cushion material is typically a single layer having length and width dimensions similar to that of the underlying mattress to which the pillowtop is attached. Typically, the foam chosen for the pillowtop is a relatively soft foam chosen for user comfort such as a viscoelastic polyurethane foam. The foam or cushion material typically has a thickness of about 2 to about 4 inches and an indention force deflection (IFD) value of about 9 to about 22 pounds-force as measured in accordance with ASTM standard D3574. IFD is a measure used in the mattress industry to describe the hardness or softness of a material, particularly in the context of foams and cushioning materials. It's considered by the industry to be a critical parameter in assessing the comfort and support qualities of these materials. The pillow top foam provides a sleeping surface for the end user and typically has a IFD much lower than the underlying mattress core.

[0005] Pillowtop mattresses can have either a smooth top surface or a quilted pillowtop. Smooth panels generally have a slightly smaller length and width dimension than the quilted pillowtop, which during manufacturing typically requires the smooth top panels to be manually stretched out and secured to meet the required finish mattress dimensions. Typically, the smooth panels would have to be secured by gluing the bottom of the pillowtop panel to the top of an underlying deck upholstery foam, which can lead to tailoring concerns.BRIEF SUMMARY

[0006] The present disclosure is directed to pillowtop mattresses and foam encased topers for pillowtop mattresses. In one or more embodiments, the foam encased topper for a pillowtop mattress includes a planar layer of foam comprising a center foam encased by a foam rail about a perimeter of the center foam, wherein the foam rail has an indention force deflection (IFD) value greater than the center foam.

[0007] In one or more embodiments, a pillowtop mattress includes a pillowtop portion and a mattress portion. The pillowtop portion includes a fabric top panel assembly including a flange about a perimeter thereof, and a foam encased topper including a planar layer of foam comprising a center foam encased by a foam rail about a perimeter of the center foam. The foam rail has an indention force deflection (IFD) value greater than the center foam. The flange from the fabric top panel assembly is affixed under tension to the foam rail. The mattress portion includes an upper deck surface, wherein the foam encased topper is adhesively coupled to the upper deck surface of the mattress and the top fabric panel assembly is sewn to a border fabric thereof.

[0008] In one or more embodiments, the pillowtop mattress includes a pillowtop portion including a foam encased topper including a planar layer of foam including a center foam encased by a foam rail about a perimeter of the center foam, wherein the foam rail has an indention force deflection (IFD) value greater than the center foam.

[0009] The disclosure may be understood more readily by reference to the following detailed description of the various features of the disclosure and the examples included therein.BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0010] Referring now to the figures wherein the like elements are numbered alike:

[0011] FIG. 1 depicts a perspective view of a completed smooth top pillowtop mattress including a foam-encased topper in accordance with one or more embodiments of the present disclosure;

[0012] FIG. 2 is a perspective view of a foam-encased topper layer in accordance with one or more embodiments of the present disclosure;

[0013] FIG. 3 is a top-down view of a foam-encased topper layer in accordance with one or more embodiments of the present disclosure; and

[0014] FIG. 4 is a cross-sectional view of a foam encased topper for a pillowtop portion of a pillowtop mattress in accordance with one or more embodiments of the present disclosure.DETAILED DESCRIPTION

[0015] Disclosed herein is a pillowtop mattress including a pillow top portion including a foam encased topper and processes of manufacture, wherein the foam encased topper generally includes a foam center encapsulated by a foam rail assembly. That is, the foam rail is disposed about a perimeter of the foam center in its entirety such that the foam rail frames the foam center layer, which defines the foam encased topper. The foam rail is selected to have a higher indention force deflection value (IFD) than the foam center, wherein the foam rail provides edge support and the foam center is tailored to provide user comfort. The foam rail and the foam center generally have the same thickness, i.e., vertical height, and can be adhesively coupled to each other to define a vertical seam between the foam rail and the foam center such that the respective top and bottom surfaces of the foam rail and the foam center are coplanar to each other.

[0016] As will be described in greater detail, the resulting foam encased topper is typically overlayed with a fabric top panel assembly including a top fabric panel, a fire-retardant knit material, a relatively thin upholstery foam, and a stretchable knit. The top fabric panel assembly further includes a flange material attached about a perimeter of the top fabric panel assembly and having a sufficient length to overlay the sidewalls of the encased foam topper. During manufacture of the pillowtop mattress, the bottom surfaces of the foam encased topper can be adhesively coupled to the deck of the underlying mattress. The fabric top panel assembly including a flange that overlies the sidewalls of the encapsulated foam topper, wherein the flange from the top fabric panel assembly is pulled downwards under tension and stapled directly into the foam rail of the foam encased topper. The fabric top panel assembly is then sewn to the border panel of the mattress to provide the pillowtop mattress.

[0017] The use of only staples to secure the flange of the fabric top panel assembly to the foam rail of the foam encased topper can eliminate the need for a gluing step commonly used in pillowtop constructions without a foam rail as described herein and advantageously simplifies manufacturing. However, a combination of staples and glue can be used or glue only can be used as may be desired for different applications. Moreover, the fabric top panel assembly can be selected to have a smooth top panel surface or a quilted top panel surface depending on the desired application. Advantageously, the pillowtop foam encased topper in accordance with the present disclosure provides the pillowtop to be made as smooth panel products, without tailoring concerns, with less glue, and with added seating support around the foam encased topper perimeter unlike prior art pillowtop constructions.

[0018] As used herein, the term “pillowtop mattress” generally refers to a type of mattress including a foam topper layer that sits on top of a mattress to provide cushioning and support to an end user. The foam topper in addition to the fabric top panel assembly defines a sleeping surface of the pillowtop mattress.

[0019] For the purposes of the description hereinafter, the terms “upper”, “lower”, “top”, “bottom”, “left,” and “right,” and derivatives thereof shall relate to the described structures, as they are oriented in the drawing figures. The same numbers in the various figures can refer to the same structural component or part thereof. Additionally, the articles “a” and “an” preceding an element or component are intended to be nonrestrictive regarding the number of instances (i.e. occurrences) of the element or component. Therefore, “a” or “an” should be read to include one or at least one, and the singular word form of the element or component also includes the plural unless the number is obviously meant to be singular.

[0020] Spatially relative terms, e.g., “beneath,”“below,”“lower,”“above,”“upper,” and the like, can be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures.

[0021] The following definitions and abbreviations are to be used for the interpretation of the claims and the specification. As used herein, the terms “comprises,”“comprising,”“includes,”“including,”“has,”“having,”“contains” or “containing,” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a composition, a mixture, process, method, article, or apparatus that comprises a list of elements is not necessarily limited to only those elements but can include other elements not expressly listed or inherent to such composition, mixture, process, method, article, or apparatus.

[0022] As used herein, the term “about” modifying the quantity of an ingredient, component, or reactant of the invention employed refers to variation in the numerical quantity that can occur, for example, through typical measuring and liquid handling procedures used for making concentrates or solutions. Furthermore, variation can occur from inadvertent error in measuring procedures, differences in the manufacture, source, or purity of the ingredients employed to make the compositions or carry out the methods, and the like.

[0023] It will also be understood that when an element, such as a layer, region, or substrate is referred to as being “on” or “over” another element, it can be directly on the other element or intervening elements can also be present. In contrast, when an element is referred to as being “directly on” or “directly over” another element, there are no intervening elements present, and the element is in contact with another element.

[0024] Referring now to FIG. 1, there is depicted a perspective view of an exemplary pillowtop mattress 10 in accordance with the present disclosure provided on a foundation 12, which includes a pillowtop portion 20 and a mattress portion 50, wherein the pillowtop portion 20 is attached to the mattress portion 50 to form the pillowtop mattress 10. As shown, the exemplary pillowtop mattress has a smooth fabric top panel. However, as noted above, the fabric top panel could be quilted depending on the desired application. In these embodiments, the exemplary pillowtop mattress 10 is generally rectangularly shaped and includes a head end (H), a foot end (F) and sides (S1, S2). The pillowtop mattress 10 may be a standard mattress size such as twin, twin XL, full, full XL, queen, Olympic queen, king, or California king or split king. It may also be a custom size. In addition, the pillowtop mattress could be a smaller mattress designed for a child or baby. Such a mattress may be part of a crib or cradle.

[0025] As shown more clearly in FIGS. 2-4, the pillowtop portion 20 includes a fabric top panel assembly 21 includes a fabric top panel 22 including a flange 24 extending about a perimeter of the fabric top panel 22 overlying a foam encased topper 30, wherein the flange is stapled using staples 26 directly to the foam rail 34 of the foam encased topper 30. The fabric top panel assembly 21 can further include a fire retardant knit (not shown), an upholstery foam (not shown), and a stretchable knit (not shown). In one or more embodiments, the flange 24 is stapled at about or below a midline of the foam rail 34. The staples 26, which are generally u-shaped are inserted horizontally into the foam rail 34. The stapler for stapling the staples into the foam rail 34 is configured to cause the staples 26 to generally flare to an angle of about 90 degrees. In one or more embodiments, the staples 26 are angled towards the ground and are horizontally spaced apart along the perimeter of the foam encased topper 30 at a distance of about 10 inches or less. Advantageously because the foam rail 34 has a relatively high IFD compared to the foam center 32 (see FIG. 3), the stapler that is used to staple the flange to the foam rail can be activated to discharge a staple into the foam rail 34 with the desired flare, unlike the prior art pillowtop portions that employ a single monolithic foam topper having relatively low IFD values. Typically, the softness associated with these single monolithic foam toppers cannot satisfactorily provide enough resistance to activate the stapler. Moreover, with regard to the use of viscoelastic monolithic foam topper, these materials are especially prone to ripping of the flange material and / or dislodgment of the staples given the tension applied to form the pillowtop portion of the pillowtop mattress.

[0026] The fabric top panel assembly 21 overlies the foam encased topper 30. The fabric top panel 22 in the assembly 21 can be any desired sheet of material, such as cotton, linen, synthetic fibers or a mixture thereof.

[0027] The foam encased topper 30 is more clearly shown in FIGS. 3-4, and includes a foam center 32 and foam rail sections 34 disposed about a perimeter thereof in their entireties of the foam center 32, which are adhesively coupled to one another to form a vertical seam 36 therebetween. Any one or combinations of these components including the various components of the fabric top panel assembly 22 may further include a phase change material, gel, and / or thermally conductive materials to provide a cooling sensation to the end user and minimize heat build-up. The phase change material (PCM) layer and / or thermally conductive materials can be coated and / or impregnated directly onto the desired layer. Likewise, any one or combinations of these various components can also include one or more various additives depending on the intended application including dyes, pigments, intumescent compounds, fire retardants, antimicrobials, fragrants, emulsifiers, preservatives, humectants, surfactants, hydrophilic agents, hydrophobic agents, and the like.

[0028] The foam center 32 is generally selected to be relatively soft to accommodate the comfort desires of the end user. In one or more embodiments, the foam center 32 has an indention force deflection (IFD) value of about 9 to about 22 pounds-force as measured in accordance with ASTM standard D3574. In other embodiments, the IDF value is from about 12 to about 20 pounds-force, and in still other embodiments, the IDF value is in a range from about 13 to 18 pounds-force. The density of the foam center 32 can generally range from about 1 to 2.5 pounds per cubic foot for non-viscoelastic foams and 1.5 to 6 pounds per cubic foot for viscoelastic foams. The thickness, i.e., vertical height, of the foam center 32 is from about 1 to about 4 inches. In one or more embodiments, the thickness is about 2 to about 4 inches and in still other embodiments, the thickness is about 3 inches. The length and width dimensions are smaller than the length and width dimensions of the underlying mattress portion to accommodate the width dimensions of the foam rail 34. Moreover, the overall length and width dimensions of the foam center 32 and foam rail 34 is generally slightly less for pillowtop mattresses including a smooth fabric top panel (i.e., non-quilted) because of the compression during assembly.

[0029] The foam center 32 can be a foam including, but not limited to, polyurethane foams, latex foams including natural, blended and synthetic latex foams; polystyrene foams, polyethylene foams, polypropylene foam, polyether-polyurethane foams, and the like. Likewise, the foam center 32 can be selected to be viscoelastic or non-viscoelastic foams. Any of these foams may be open celled or closed cell or a hybrid structure of open cell and closed cell. Likewise, the foams can be reticulated or partially reticulated or non-reticulated. Still further, the foams may be gel infused in some embodiments. The term reticulation generally refers to removal of cell membranes to create an open cell structure that is open to air and moisture flow. Still further, the foam center 32 can be formed of one or more layers. The different layers can be formed of the same material configured with different properties or different materials. In one or more embodiments, the foam center 32 is a monolithic viscoelastic foam. Optionally, the foam center 32, e.g., viscoelastic foam, can further include a phase change material and / or thermally conductive materials to provide a cooling sensation to the end user and minimize heat build-up.

[0030] The foam rail 34 framing the foam center 32 has a higher IFD than the foam center 32 to provide edge support. In one or more embodiments, the foam rail 34 has an IFD within a range from about 28 to about 40 pounds-force. In other embodiments, the IFD within a range from about 32 to about 36 pounds-force and in still other embodiments, IFD is about 34 pounds-force. As previously noted, the thickness, i.e., height, of the foam rail 34 is the same as the foam center 32 such that the respective top and bottom surfaces are coplanar to one another. The width of the foam rail 34 is in a range from about 2 to about 4 inches. The foam rail 32 can be composed of one or more foam layers (i.e., a foam laminate) and is adhesively coupled to the sidewalls of the foam center 32 to form a vertical seam 36 therebetween and define the foam encased topper. The foam rail 34 can be a one-piece construction or formed of two or more sections. For ease in manufacturing, multiple sections of the foam rail 34 are provided and assembled, wherein each foam rail section defining the foam rail 34 is linear. As shown in FIG. 3, the foam rail 34 includes side rails 38 extending a length dimension of the foam center 32 and end rails 40 at the head (H) and foot ends (F).

[0031] The foam rail 34 can be a foam including, but not limited to, non-viscoelastic foams such as polyurethane foams, latex foams including natural, blended and synthetic latex foams; polystyrene foams, polyethylene foams, polypropylene foam, polyether-polyurethane foams, and the like. Any of these foams may be open celled or closed cell or a hybrid structure of open cell and closed cell. Likewise, the foams can be reticulated or partially reticulated or non-reticulated. The term reticulation generally refers to removal of cell membranes to create an open cell structure that is open to air and moisture flow. Still further, the foams may be gel infused in some embodiments. Moreover, the foam rail 34 can be formed of one or more layers. The different layers can be formed of the same material configured with different properties or different materials. Optionally, the foam can further include a phase change material and / or thermally conductive materials to provide a cooling sensation to the end user and minimize heat build-up.

[0032] The particular process for forming the pillowtop mattress is not intended to be limited. An exemplary process of manufacturing the pillowtop mattress generally includes providing a mattress 50, which can be formed of foam, coil springs, air bladders, or combination thereof to provide a deck for attachment of the pillowtop portion 20. The pillowtop portion 20 is formed by first adhesively coupling the various foam rail 34 sections to the foam center 32, which may require stretching of the center foam to form the foam encased toper 30. The foam encased topper 30 can be adhesively coupled to the deck of the underlying mattress. The fabric top panel assembly 21, e.g., including smooth fabric top panel and flange attached about a perimeter are then positioned over the foam encased topper 30, wherein the flange 24 is stapled to the foam rail 34 under downward tension. The fabric top panel assembly 21 is then sewn to the border to the mattress to form the pillowtop mattress.

[0033] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to make and use the invention. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.

Claims

1. A foam encased topper for a pillowtop mattress assembly comprising:a planar layer of foam comprising a foam center encased by a foam rail about a perimeter of the foam center, wherein the foam rail has an indention force deflection (IFD) value greater than the foam center.

2. The mattress topper of claim 1, wherein the foam center has an IFD in a range from 9 to 22 pounds-force and the foam rail has an IFD in a range from 28 to 40 pounds-force.

3. The mattress topper of claim 1, wherein the foam center is a viscoelastic foam and the foam rail is a non-viscoelastic polyurethane foam.

4. The mattress topper of claim 1, wherein the foam center and / or the foam rail is a foam laminate comprising multiple foam layers.

5. The mattress topper of claim 3, further comprising a phase change material on or impregnated in any one or combination of the foam center, and the foam rail.

6. The mattress topper of claim 1, wherein the foam rail comprises polyurethane, latex, polystyrene, polyethylene, or polypropylene.

7. A pillowtop mattress comprising:a pillowtop portion, wherein the pillowtop portion comprises a fabric top panel assembly including a flange about a perimeter thereof, a foam encased topper including a planar layer of foam comprising a foam center encased by a foam rail about a perimeter of the foam center, wherein the foam rail has an indention force deflection (IFD) value greater than the foam center, wherein the flange from the fabric top panel assembly is affixed under tension to the foam rail; anda mattress portion comprising an upper deck surface, wherein the foam encased topper is adhesively coupled to the upper deck surface and the top fabric panel assembly is sewn to a border fabric thereof.

8. The pillowtop mattress of claim 7, wherein the flange is affixed under tension to the foam rail with staples.

9. The pillowtop mattress of claim 8, wherein the staples are horizontally stapled at or below a midline of the foam rail and are spaced apart by a distance of 10 inches or less.

10. The pillowtop mattress of claim 7, wherein the foam encased topper comprising the foam center and the foam rail are adhesively coupled to form a vertical seam therebetween.

11. The pillowtop mattress of claim 7, wherein the foam center has an IFD in a range from 9 to 22 pounds-force and the foam rail has an IFD in a range from 28 to 40 pounds-force.

12. The pillowtop mattress of claim 7, wherein the foam center is a viscoelastic foam and the foam rail is a polyurethane foam.

13. The pillowtop mattress of claim 7, wherein the foam center and / or the foam rail is a foam laminate comprising multiple foam layers.

14. The pillowtop mattress of claim 7, further comprising a phase change material on or impregnated in any one or combination of the fabric top panel assembly, the foam center, and the foam rail.

15. The pillowtop mattress of claim 7, wherein the foam rail comprises polyurethane, latex, polystyrene, polyethylene, or polypropylene.

16. The pillowtop mattress of claim 7, wherein the fabric top panel assembly provides a smooth surface.

17. The pillowtop mattress of claim 7, wherein the fabric top panel assembly comprises a fabric top panel, a flame retardant knit, an upholstery foam, and a stretchable knit, wherein the upholstery foam is sandwiched between the flame retardant knit and the stretchable knit to form a subassembly that underlies the top fabric panel.

18. A pillowtop mattress comprising:a pillowtop portion comprising a foam encased topper including a planar layer of foam comprising a foam center encased by a foam rail about a perimeter of the center foam, wherein the foam rail has an indention force deflection (IFD) value greater than the foam center.

19. The pillowtop mattress of claim 18, wherein the foam center has an IFD in a range from 9 to 22 pounds-force and the foam rail has an IFD in a range from 28 to 40 pounds-force.

20. The pillowtop mattress of claim 18, wherein the foam rail has a width of 2 to 4 inches and a height of 2 to 4 inches, and the center foam includes top and bottom planar surfaces coplanar to the top and bottom surfaces of the foam rail.

Images