Mattress covering

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Solution Overview

Problem

Traditional mattress covers often have limited stretch, causing them to pull on interior mattress components and leading to permanent deformation and wear of foam materials.

Innovation Solution

A mattress cover system featuring multiple layers of stretch fabrics with different material properties, including a first stretch fabric around the perimeter, a four-way stretch fabric on the top, and additional stretch fabrics between these layers, allowing for multidirectional stretching and improved recovery from compression.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional mattress covers with limited stretch are used, then the cover structure is simple, but the cover pulls on interior mattress components causing permanent deformation and wear of foam materials

Engineering Contradiction:

Improvefoam material durabilityVSAvoidmattress cover structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The mattress cover is divided into multiple fabric layers with different stretch characteristics. The first stretch fabric layer has a first predominant stretch direction, while the second stretch fabric layer has a second predominant stretch direction different from the first. This segmentation allows each layer to handle different types of stress and deformation, preventing the cover from pulling on foam materials while maintaining structural integrity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The mattress cover uses composite fabric structures combining multiple stretch fabrics with different material properties. The combination of fabrics with different predominant stretch directions creates a composite material system that provides multidirectional stretch capability, accommodating foam tolerance and recovery without causing permanent deformation.

Inventive Principle:

Principle #40Composite materials

2Adaptability or versatility

If single-layer stretch fabric is used, then the cover is easy to manufacture, but it cannot accommodate foam tolerance and recovery from flexing and compression

Engineering Contradiction:

Improvefoam tolerance accommodationVSAvoidcover manufacturing process

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The cover is segmented into multiple fabric layers, each with specific stretch directions. The first stretch fabric layer provides stretch in a first predominant direction, while the second stretch fabric layer provides stretch in a second predominant direction different from the first. This segmentation enables the cover to accommodate foam tolerance and recovery from flexing and compression in multiple directions.

Inventive Principle:

Principle #1Segmentation

3Shape

If limited stretch fabric is used, then the cover maintains structural stability, but it causes wrinkles and poor fit aesthetics

Engineering Contradiction:

Improvecover fit and appearanceVSAvoidcover structural stability

Core Design Contradiction:

ShapeVSStability of the object's composition

Solution Approach 1:

The mattress cover employs dynamic fabric layers with different predominant stretch directions that can adapt to mattress deformation. The first stretch fabric layer stretches in a first predominant stretch direction, while the second stretch fabric layer stretches in a second predominant stretch direction different from the first. This dynamic multi-directional stretch capability allows the cover to maintain smooth appearance and proper fit while accommodating structural changes.

Inventive Principle:

Principle #15Dynamics

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The mattress cover system reduces permanent deformation and wear of foam materials by accommodating foam tolerance and recovery from flexing and compression, while also providing improved aesthetics by minimizing wrinkles and ensuring a better fit.

Implementation Method 1

The first stretch fabric has a first predominant stretch direction that is stretchable in a direction parallel to the mattress top

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

A four-way stretch fabric is configured to be positioned on the mattress top

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS12336635B2Mattress covering

Publication Date: 2025.06.24 SLEEP NUMBER CORP

AI summary

A bed has a mattress with a mattress top, a mattress bottom, and a mattress perimeter. The mattress includes a mattress cover surrounding the mattress. The mattress cover includes a first stretch fabric around the mattress perimeter of the mattress. The first stretch fabric has a first predominant stretch direction that is stretchable in a direction parallel to the mattress top. A multidirectional stretch fabric is positioned on the mattress top.