MATTRESS TOPPER

Abstract

A mattress topper for use with a mattress includes a first planar layer having a first firmness; a second planar layer having a second firmness; wherein the second firmness is different than the first firmness; a peripheral edge layer connected with both the first and second layers and having a third firmness, wherein the peripheral edge layer follows perimeters of each of the first and second planar layers and wherein the first planar layer, second planar layer, and peripheral edge layer define an interior cavity; and an inner layer encapsulated within the interior cavity, and wherein the first and second planar layers have an interior surface adjacent to the interior cavity and an exterior surface opposite the interior surface.

Claims

1. A mattress topper for use with a mattress, comprising: a first planar layer having a first firmness; a second planar layer having a second firmness; wherein the second firmness is different than the first firmness; a peripheral edge layer connected with both the first and second layers and having a third firmness, wherein the peripheral edge layer follows perimeters of each of the first and second planar layers and wherein the first planar layer, second planar layer, and peripheral edge layer define an interior cavity; and an inner layer encapsulated within the interior cavity, wherein the first and second planar layers have an interior surface adjacent to the interior cavity and an exterior surface opposite the interior surface and wherein the distance between the exterior surface of the first planar layer and the exterior surface of the second planar layer is not more than 4 inches.

2. The mattress topper of claim 1, wherein the third firmness is at least equal to the higher of the first and second firmness.

3. The mattress topper of claim 1, wherein the third firmness is at least equal to the lower of the first and second firmness.

4. The mattress topper of claim 1, wherein the third firmness is less than the lower of the first and second firmness.

5. The mattress topper of claim 1, wherein the inner layer comprises a first material having a first air permeability and the first planar layer, the second planar layer, and the peripheral edge layer comprise one or more materials each having an air permeability less than the first air permeability.

6. The mattress topper of claim 1, wherein the inner layer comprises a first material having a first air permeability and the first planar layer, second planar layer, and peripheral edge layer comprise one or more materials each having an air permeability greater than the first air permeability.

7. The mattress topper of claim 1, wherein the inner layer comprises at least one of a polyester fiber layer, a cotton layer, a wool cashmere layer, a non-organic fibrous layer, an organic fibrous layer, an air chamber, and a water chamber.

8. The mattress topper of claim 1, wherein the inner layer comprises at least two layers of material.

9. The mattress topper of claim 7, wherein the inner layer comprises at least one air chamber and further comprising a pump in fluid communication with an inlet of the at least one air chamber and configured to supply a flow of air to the at least one air chamber to maintain a positive pressure within the at least one air chamber.

10. The mattress topper of claim 1, wherein the first planar layer and the second planar layer are fixedly attached to the peripheral edge layer.

11. The mattress topper of claim 10, wherein the first and second planar layers are permanently bonded to the peripheral edge layer.

12. The mattress topper of claim 10, wherein the first and second planar layers are removable from the peripheral edge layer.

13. The mattress topper of claim 1, wherein the mattress topper is configured to be selectively positioned in: a first orientation wherein the first planar layer is positioned on top of the peripheral edge layer and the second planar layer, thereby representing a top side of the mattress topper when placed on a mattress; and a second orientation wherein the second planar layer is positioned on top of the peripheral edge layer and the first planar layer, thereby representing the top side of the mattress topper when placed on the mattress.

14. The mattress topper of claim 1, wherein perforations extend through at least one of the first planar layer and the second planar layer.

15. The mattress topper of claim 1, wherein the peripheral edge layer consists of two or more separate components, and wherein each component follows a portion of the perimeters of the first and second planar layers and combine with the other components of the peripheral edge layer to enclose sides of the inner layer.

16. The mattress topper of claim 1, wherein at least one of the first planar layer and the second planar layer comprise at least one convoluted surface.

17. The mattress topper of claim 1, wherein at least one of the first planar layer and the second planar layer comprise at least one textured surface.

18. A method for making a mattress topper for use with a mattress comprising the steps of: providing a first planar layer; connecting a peripheral edge layer with the first planar layer; placing an inner layer within the peripheral edge layer; connecting a second planar layer with the peripheral edge layer opposite the first planar layer; wherein a perimeter of peripheral edge layer follows perimeters of the first planar layer and the second planar layer; and wherein the peripheral edge layer, the first planar layer, and the second planar layer define an interior cavity, and wherein the inner layer is positioned in the interior cavity.

19. The method for making a mattress topper of claim 18, wherein the inner layer comprises a material having a first air permeability and the first planar layer, second planar layer, and peripheral edge layer comprise one or more materials each having an air permeability less than the first air permeability.

20. The method for making a mattress topper of claim 18, wherein the inner layer comprises multiple fibrous layers, and further comprising the step of connecting the multiple fibrous layers at edges of each of the multiple fibrous layers.

21. The method for making a mattress topper of claim 18, wherein the inner layer comprises at least one air chamber having an inlet and further comprising the steps of: connecting a hose to a pump configured to provide a constant or selective flow of air through the hose; connecting the hose with the inlet of the at least one air chamber; and providing a flow of air to the at least one air chamber from the pump and through the hose to increase an air pressure within the at least one air chamber to provide the at least one air chamber with a desired firmness and/or maintain a positive air pressure in the at least one air chamber.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0015] FIG. 1 is a perspective view of a mattress topper in use on a mattress according to an embodiment of the present disclosure.

[0016] FIG. 2 is a perspective view of a mattress topper according to an embodiment of the present disclosure.

[0017] FIG. 3 is an exploded partial cutaway view of a mattress topper according to an embodiment of the present disclosure.

[0018] FIG. 4 is a top view of a mattress topper according to an embodiment of the present disclosure.

[0019] FIG. 5 is a side view of the mattress topper of FIG. 4.

[0020] FIG. 6 is a cross-sectional view of the mattress topper of FIG. 4 taken along the line A-A.

[0021] FIG. 7 is a cross-sectional view of a mattress topper according to an embodiment of the present disclosure.

[0022] FIG. 8 is a cross-sectional view of the mattress topper of FIG. 4 taken along the line B-B in FIG. 5.

[0023] FIG. 9 is a perspective view of a mattress topper with an air supply according to another embodiment of the present disclosure.

[0024] FIG. 10 is a top view of the mattress topper of FIG. 9.

[0025] FIG. 11 is a cross-sectional view of the mattress topper of FIG. 9 along the line C-C of FIG. 10.

DETAILED DESCRIPTION

[0026] The present teachings are described more fully hereinafter with reference to the accompanying drawings, in which the present embodiments are shown. The following description is presented for illustrative purposes only and the present teachings should not be limited to these embodiments.

[0027] Generally, all terms used in the claims are to be interpreted according to their ordinary meaning in the technical field, unless explicitly defined otherwise herein. All references to a/an/the element, apparatus, component, means, step, etc., are to be interpreted openly as referring to at least one instance of the element, apparatus, component, step, etc., unless explicitly stated otherwise. The steps of any method disclosed herein do not have to be performed in the exact order disclosed, unless explicitly stated. The use of first, second, etc. for different features/components of the present disclosure are only intended to distinguish the features/components from other similar features/components and not to impart any order or hierarchy to the features/components.

[0028] Any direction referred to herein, such as top, bottom, left, right, upper, lower, above, below, and other directions and orientations are described herein for clarity in reference to the figures and are not to be limiting of an actual device or system or use of the device or system. Many of the devices, articles, or systems described herein may be used in a number of directions and orientations.

[0029] FIG. 1 illustrates a mattress topper assembly 100 according to embodiments of the present disclosure which is installed on a mattress 200. The mattress topper 100 is constructed to provide extra support and comfort to the mattress 200. The mattress topper 100 may comprises a first planar layer 110, a second planar layer 120, a peripheral edge layer 130, and an inner layer 140 (see FIG. 3). The first planar 110, second planar 120, and peripheral edge layer 130 may be rectangular in shape. In other embodiment the dimensions and shape of the mattress topper 100 may be adjusted to fit any size or shape mattress 200. In the embodiment depicted in FIG. 1 the second planar layer 120 is in contact with the mattress 200. The peripheral edge layer 130 sits above the second planar layer 120 and underneath the first planar layer 110. In yet another embodiment the mattress topper may be reversible, where for example, the first planar layer 110 is in contact with the mattress 200 and the second planar layer 120 is the top surface 112.

[0030] In the preferred embodiment the first planar layer 110, second planar layer 120, and the peripheral edge layer 130 of the mattress topper 100 are formed of a compressible material typically a foam. In one embodiment of the mattress topper 100, the second planar layer 120 and the first planar layer 110 are made of foam materials, one or both of which may be gel memory foam materials. The second planar layer 120 may be made of a foam with a higher firmness than the first planar layer 110 or vice versa. The peripheral edge layer 130 may consist of a foam having a firmness as the first 110 or second planar layer 120, preferably at least equal to the firmness of whichever planar layer 110/120 has the higher firmness, that allows the peripheral edge layer 130 to provide support to the edge of the mattress topper 100. In another embodiment if desired the first planar layer 110 may be firmer than the second planar layer 120, and the peripheral edge layer 130 may be firmer than the second planar layer 120 but less firm than the first planar layer 110.

[0031] In another embodiment, a convoluted foam with at least one convoluted side may be used for the first planar layer 110, the second planar layer 120, or both planar layers. In the particular embodiment of FIG. 3, an inner, planar side of the convoluted first planar layer 110 may be in contact with the inner layer 140, while the convoluted side faces up and towards the user. In yet another embodiment, the convoluted side of the first planar layer 110 may be in contact with the inner layer 140. However, in other embodiments, both sides of the layer of foam may be convoluted or the convoluted foam may be used for the second planar layer 120 or both planar layers together. In yet another embodiment a textured foam layer may be used for the first 110 and/or second 120 planar layer, wherein the textured foam layer may have a pattern of groves or valleys cut or incised into at least one of the planar surfaces. In one embodiment, a computer numerical control (CNC) machine is used to incise or otherwise cut the foam. In another embodiment, the textured foam layer may be embossed with a decorative or functional raised pattern. Embodiments incorporating a convoluted foam or textured foam would enable the mattress topper 100 to more effectively distribute the user's weight and/or enhance air flow between the user and the mattress topper 100.

[0032] The illustrated embodiments of FIG. 2 and FIG. 3 depict perspective views of the mattress topper 100. Referring to FIG. 3, an exploded perspective view is shown where a section of the peripheral edge layer 130 has been removed for clarity. In the illustrated embodiment, the peripheral edge layer 130 defines the perimeter of an interior cavity 150, wherein the interior cavity 150 is located between a first boundary created by the first planar layer 110 and a second boundary created by the second planar layer 120. The interior cavity 150 of the illustrated embodiment encapsulates an inner layer 140, wherein the inner layer 140 comprises an upper material layer 142 and a lower material layer 144. The first planar layer 110 is fixed to the top surface 112 of the peripheral edge layer 130. The second planar layer 120 is fixed to the bottom surface 122 of the peripheral edge layer 130. The first 110 and/or second 120 planar layers may be fixed to the peripheral edge layer 130 in a selectively removable relationship, for example with one or more zippers, hook and loop material, such as Velcro, an enclosing envelope or shell, or other means that allow for temporary fixation of the first 110 and second 120 planar layers to the peripheral edge layer 130 while also allowing the first 110 and/or second 120 planar layers to be removed from the peripheral edge layer 130. These embodiments may allow for replacement of the inner layer 140 and/or interchanging of one type of inner layer 140 material with a different type of material. For example, the material of the inner layer 140 may be exchanged if a different air permeability or firmness is desired for the inner layer 140.

[0033] Alternately, the first planar layer 110 and/or the second planar layer 120 may be fixed to the peripheral edge layer 130 in a permanent relationship in which the first 110 and/or second 120 planar layers are not removable from the peripheral edge layer 130, for example, using an adhesive material, sewing, or other permanent methods. The construction of the mattress topper 100 in preferred embodiments results in the inner layer 140 free floating within the interior cavity 150. This allows the mattress topper 100 to conform to the user and reduces the impact to comfort that occurs when using a firmer foam layer in a mattress topper 100.

[0034] In the preferred embodiment, the upper material layer 142 and lower material layer 144 are made of a low meld fiber. The fiber layers are heated in an oven resulting in their edges melding together. In other embodiments, the inner layer 140 may have a compressible construction comprising, for example, one more of an air chamber(s), water chamber(s), polyester fiber layer, cotton layer, wool cashmere layer, other organic fibrous materials, other non-organic fibrous materials, Gellux foam, gel memory foam, or another compressible foam. In another embodiment, the inner layer 140 may comprise only one layer as show in the cross-sectional view of FIG. 6. In yet another embodiment, the inner layer 140 may comprise two or more material layers as shown in FIG. 7, wherein the inner layer 140 comprises a first layer 342, a second layer 344, a third layer 346, and a fourth layer 348. In embodiments wherein the inner layer 140 comprises multiple layers, each layer may be a different material. The material(s) for the inner layer 140 is/are selected based on at least one of the firmness and air permeability of the material. In a preferred embodiment, the material selected for the inner layer 140 has a greater fabric porosity or air permeability than the encapsulating foam layers resulting in an increased airflow through the inner layer 140 when all layers of the mattress topper 100 are subjected to the same pressure differential, i.e., the weight of a user introduced onto the mattress topper 100. However, in other embodiments, materials may be chosen for the inner layer 140 that result in a lower air permeability than the encapsulating foam layers. An additional embodiment of the mattress may include perforations through the first, second, or both planar layers. These perforations may be spaced over the entirety of the planar layer's surface area or limited to certain areas of the planar layer, for example, avoiding the portions of the planar layer aligned with the peripheral edge layer 130.

[0035] The illustrated embodiment FIG. 8 depicts another embodiment of the mattress topper 100 wherein another embodiment of the peripheral edge layer 830 comprises a first rail 832, second rail 834, third rail 836, and fourth rail 838. The four rails are separate components and are joined to the first planar 110 and second planar 120 layers, as well as each other to form the peripheral edge layer 830.

[0036] FIG. 9 illustrates another embodiment of the mattress topper 100 where a pump 970 is fluidly connected with an inlet of the interior cavity 150 and/or with an inlet of one or more air chambers 975 contained within the interior cavity 150, for example, by a hose 972. In another embodiment the pump may be mounted into the sidewall of the peripheral edge layer 130 or within the interior cavity 150. The pump 970 provides a flow of air into the interior cavity 150 and/or air chamber 975 of the mattress topper 100 to from the pump and through the hose to increase air pressure within the interior cavity 150 and/or air chamber to provide and/or maintain the a positive air pressure within the interior cavity 150 and/or air chamber 975 that results in a desired firmness of the mattress topper 100 and/or air chamber 975. The cross-sectional view of FIG. 11 shows an embodiment where the hose 972 extends through the outer peripheral edge sidewall 132 to engage an inlet of an air chamber 134. The illustrated embodiment of FIG. 11 also depicts an air chamber 975 contained within the interior cavity 150, wherein the walls of the air chamber 975 are positioned with a gap between the walls of the interior cavity 150. In another embodiment the walls of the air chamber 975 contact the walls of the interior cavity 150. In yet another embodiment the air chamber 975 is split into multiple sealed air chambers.

[0037] While the present teachings have been described above in terms of specific embodiments, it is to be understood that they are not limited to these disclosed embodiments. Many modifications and other embodiments will come to mind to those skilled in the art to which this pertains, and which are intended to be and are covered by both this disclosure and the appended claims. It is intended that the scope of the present teachings should be determined by proper interpretation and construction of the appended claims and their legal equivalents, as understood by those of skill in the art relying upon the disclosure in this specification and the attached drawings.