Abstract:
A topper for use with a bedding or seating product, such as a mattress, comprises a casing surrounding a pocketed spring assembly and at least one cushioning layer. The topper has a skirt which may fit around the mattress. The skirt may have a drawstring or an elastic band which helps keep the removable topper on top of the bedding or seating product. The height of the springs in the pocketed spring assembly is typically less than the height of the bedding or seating product.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    This invention relates generally to bedding or seating products and, more particularly, to a mattress topper or pad for use in on a finished mattress. 
         [0002]    Traditionally, toppers for mattresses have consisted of relatively thin members which may be removed from the mattress for a variety of purposes. U.S. Pat. No. 6,009,579 discloses a topper for a feather bed. U.S. Pat. No. 6,922,862 discloses a topper designed to be placed on top of a conventional mattress. 
         [0003]    One drawback of known toppers for use with conventional mattresses is that the toppers are not durable enough and may have to be replaced frequently. 
         [0004]    In order to achieve greater durability in a topper adapted to be removed from a bedding or seating product, such as a mattress, it would be desirable to include a pocketed spring assembly into the topper. Therefore, making a topper having a pocketed spring assembly incorporated therein, the topper being sold separately from a mattress, would be desirable. 
       SUMMARY OF THE INVENTION 
       [0005]    This invention provides a mattress pad or topper which may be sold separately from a finished bedding or seating product, such as a mattress. The present invention is not intended to be limited for use with any particular bedding or seating product. For example, the mattress topper of the present invention may be used with a mattress having an innerspring core or a foam core or any combination thereof. 
         [0006]    According to one aspect of the present invention, a mattress topper may be used with any mattress. The mattress topper comprises a bucket or casing comprising a bottom and sides. A pocketed spring assembly is located inside the bucket. At least one cushioning layer may be located above the pocketed spring assembly. The mattress topper further comprises a quilted top layer and a skirt adapted to fit around a mattress. The bucket, skirt and quilted top layer are sewn together. In some instances, inner edges of the bucket, skirt and quilted top layer may be taped together before being sewn together. 
         [0007]    The skirt of the mattress topper may have an elastic band or draw string sewn therein to better secure the mattress topper around the mattress. 
         [0008]    One or more of the cushioning layers may be polyurethane or latex or memory foam or any other type of foam. One or more of the cushioning layers may alternatively or collectively be a layer of fiber batt or down for insulation purposes. Another type of cushioning layer may be a gel layer. 
         [0009]    In some versions of the mattress topper, cushioning materials are located only above the pocketed spring assembly. However, in other versions of the mattress topper, cushioning or insulating materials may be located above and below the pocketed spring assembly. 
         [0010]    According to another aspect of the present invention, a mattress may be used in combination with a mattress topper. The mattress topper may be removed from the mattress without disturbing the mattress. The mattress topper may comprise a casing surrounding a pocketed spring assembly; at least one cushioning layer and a quilted top layer. The mattress topper may further comprise a skirt sized or adapted to fit around or surround the mattress. The skirt may have an elastic band or drawstring at the bottom of the skirt. The cushioning layer may include one or more layers of foam and/or fiber. The cushioning layer(s) may cover one or opposed surfaces of the pocketed spring assembly. The casing, skirt and quilted top layer may be sewn together. 
         [0011]    Although several types of mattress topper have been described herein, any of the mattress toppers shown or described herein may be used in any bedding or seating product, including a mattress. For example, the topper may be used in a seat cushion, such as a car seat. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]    The objectives and features of the invention will become more readily apparent from the following detailed description taken in conjunction with the accompanying drawings in which: 
           [0013]      FIG. 1  is a perspective view of a mattress topper according to one embodiment on top of a mattress; 
           [0014]      FIG. 2  is a perspective view, partially broken away, of the mattress topper of  FIG. 1  pulled away from the mattress of  FIG. 1 ; 
           [0015]      FIG. 3  is a cross-sectional view taken along the line  3 - 3  of  FIG. 1 , the mattress being shown in phantom; 
           [0016]      FIG. 4  is an enlarged cross-sectional view of the encircled area  4  of  FIG. 3 ; 
           [0017]      FIG. 4A  is an enlarged view like  FIG. 4  of an alternative seam; 
           [0018]      FIG. 5  is a perspective view, partially broken away, of another embodiment of mattress topper pulled away from a mattress; 
           [0019]      FIG. 6  is a cross-sectional view of the mattress topper of  FIG. 5  on a mattress, the mattress being shown in phantom; 
           [0020]      FIG. 7  is a perspective view, partially broken away, of another embodiment of mattress topper pulled away from a mattress; 
           [0021]      FIG. 8  is a cross-sectional view of the mattress topper of  FIG. 7  on a mattress, the mattress being shown in phantom; 
           [0022]      FIG. 9  is a perspective view, partially broken away, of another embodiment of mattress topper pulled away from a mattress; 
           [0023]      FIG. 10  is a cross-sectional view of the mattress topper of  FIG. 9  on a mattress, the mattress being shown in phantom; 
           [0024]      FIG. 11  is a perspective view, partially broken away, of another embodiment of mattress topper pulled away from a mattress; 
           [0025]      FIG. 11A  is an enlarged view of the encircled area of  FIG. 11 ; and 
           [0026]      FIG. 12  is a cross-sectional view of the mattress topper of  FIG. 11  on a mattress, the mattress being shown in phantom. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0027]    Referring to the drawings and, particularly to  FIG. 1 , a mattress topper  10 , according to one embodiment of this invention, is shown in connection with a bedding or seating product in the form of a mattress  12 . As shown in  FIG. 1 , the mattress  12  has a longitudinal dimension or length L and a transverse dimension or width W. Although the length L is shown as being greater than the width W, they may be identical. As shown in  FIG. 1 , the combination of mattress topper  10  and mattress  12  has a height H. 
         [0028]    The mattress  12  may be any known mattress and is not intended to be limited to any particular mattress. For example, the mattress  12  may include a spring core or spring assembly or may be entirely foam. The mattress topper  10  of the present invention may be used in connection with any adjustable bed mattress or sofa sleeper mattress also. 
         [0029]    The mattress topper  10  need not be sold with a mattress or other bedding or seating product. The mattress topper  10  may be sold separately and replaced at any desired time.  FIG. 2  illustrates one embodiment of mattress topper  10  separated from a mattress  12 . As shown in  FIGS. 2 and 3 , the mattress topper  10  comprises a bucket or casing  14  having a bottom  16  and sides  18 . As shown in  FIG. 4 , an upper portion  20  of each bucket side  18  may be turned inwardly at location  22  to a generally horizontal orientation for assembly purposes, as described below. 
         [0030]    As best shown in  FIGS. 2 and 3 , the mattress topper  10  further comprises a pocketed spring assembly  24  inside the bucket or casing  14 . As shown in  FIG. 2 , pocketed spring assembly  24  comprises a plurality of longitudinally extending strings  26  of individually pocketed springs joined together and extending from end-to-end of the mattress topper  10 . Alternatively, the strings of individually pocketed springs may extend transversely or from side-to-side inside the bucket  14  of the mattress topper  10 . As shown in  FIG. 3 , each string of pocketed springs  16  comprises a row of individual fabric pockets  28 , each containing at least one spring  30 . Although one pocketed spring assembly is illustrated, any known pocketed spring assembly may be used including the one disclosed in U.S. Pat. No. 8,087,114, for example. Any of the mattress toppers shown or described herein are not intended to limit the pocketed spring assembly incorporated therein. 
         [0031]    As shown in  FIGS. 2 and 3 , mattress topper  10  further comprises a first cushioning layer of polyurethane foam  32  below the pocketed spring assembly  24  inside the bucket or casing  14  immediately above the bottom  16  of the bucket or casing  14 . The mattress topper  10  further comprises a second cushioning layer of polyurethane foam  34  above the pocketed spring assembly  24 . Each of the cushioning layers of polyurethane foam  32 ,  34  may be any desired depth. However, in one embodiment, the depth of each cushioning layer of polyurethane foam  32 ,  34  is one-half inch. As an alternative, any type of foam, including but not limited to memory foam, may be used for one or both of the cushioning layers  32 ,  34 . 
         [0032]    Another component of the mattress topper  10  is a quilted top layer or fiber panel  36 . As best shown in  FIGS. 3 and 4 , this quilted fiber panel  36  comprises an outer fabric layer  38  surrounding a fiber interior  40  sewn together along seams  42  which assume any desired pattern. 
         [0033]    As shown in  FIGS. 2 and 3 , mattress topper  10  further comprises a skirt  44  adapted to fit around mattress  12 . At its bottom, the skirt  44  has an elastic band  46  adapted to fit underneath mattress  12  so that the skirt  44  stays on top of the mattress  12 . As shown in  FIG. 3 , the skirt  44  extends from a combination seam  48  shown in detail in  FIG. 4  downwardly along the sides  50  of the mattress  12  and along the lower surface  52  of the mattress  12 . 
         [0034]      FIG. 4  illustrates the details of the combination seam  48  which joins together the elements of the mattress topper  10  and, more particularly, the bucket  14 , the skirt  44  and the quilted upper layer  36 . As shown in  FIG. 4 , tape  54  is wrapped around outer edges of the bucket  14 , the skirt  44  and the quilted upper layer  36 . The combination seam  48  joins together the upper generally horizontally oriented portion  20  of sidewalls  18  of bucket  14  below a bent generally horizontally oriented upper portion  56  of skirt  44  and an outer generally horizontally oriented portion  58  of the quilted top layer or fiber panel  36 . The generally horizontally oriented portion  58  of the quilted top layer or fiber panel  36  is located above the generally horizontally oriented upper portion  56  of skirt  44 . 
         [0035]      FIG. 4A  illustrates the details of another combination seam  48   a  which may join together the elements of the mattress topper  10  and, more particularly, the bucket  14 , the skirt  44  and the quilted upper layer  36 . As shown in  FIG. 4A , tape  54  is wrapped around outer edges of the bucket  14 , the skirt  44  and the quilted upper layer  36 . The combination seam  48   a  joins together an edge portion  20   a  of sidewall  18  of bucket  14 , an edge portion  56   a  of skirt  44  and an edge portion  58   a  of the quilted top layer or fiber panel  36  along with the tape  54 . As shown in  FIG. 4A , the edge portion  58   a  of the quilted top layer or fiber panel  36  is located between the edge portion  20   a  of sidewall  18  of bucket  14  and the edge portion  56   a  of skirt  44 . Once, the edge portion  58   a  of the quilted top layer  36  and the edge portion  20   a  of sidewall  18  of bucket  14  and the edge portion  56   a  of skirt  44  are sewn together with the tape  54  with combination seam  48   a,  the sidewall  18  of bucket  14  is bent at location  66  downwardly to form an inverted U-shape outside the combination seam  48   a . Similarly, the skirt  44  is bent at location  68  downwardly to form an inverted U-shape outside the combination seam  48   a.    
         [0036]      FIGS. 5 and 6  illustrate an alternative embodiment of mattress topper  10   a  identical to the mattress topper  10 , but omitting the lower cushioning layer  32 . 
         [0037]      FIGS. 7 and 8  illustrate an alternative embodiment of mattress topper  10   b  identical to the mattress topper  10 , but including two additional cushioning layers  60 ,  62 . Each of the cushioning layers  60 ,  62  comprises fiber batt. As illustrated in  FIG. 8 , cushioning layer  60  is located between the quilted top layer or fiber panel  36  and the upper foam cushioning layer  34 . Similarly, cushioning layer  62  is located between the bottom  16  of the casing  14  and the lower foam cushioning layer  32 . 
         [0038]      FIGS. 9 and 10  illustrate an alternative embodiment of mattress topper  10   c  identical to the mattress topper  10 , but having a non-quilted top layer  64  in place of a quilted top layer. The non-quilted top layer  64  may be made of any desired material. In either of the combination seams  48 ,  48   a  shown in  FIGS. 4 and 4A , a non-quilted top layer  64  may be inserted in place of a quilted top layer. 
         [0039]      FIGS. 11 and 12  illustrate an alternative embodiment of mattress topper  10   d  identical to the mattress topper  10 , but having a different pocketed spring assembly  24   d  in place of pocketed spring assembly  24 . The pocketed spring assembly  24   d  need not be made of strings of individually pocketed springs joined together. Rather the pocketed spring assembly  24   d  may comprise a blanket of individually pocketed springs, each spring  30   d  being in a pocket  28   d.  Although the springs  30   d  shown in pockets  28   d  are illustrated as being shorter than the springs  30  in pockets  28  of the mattress topper  10 , they may be any desired size. As shown in  FIG. 12 , pockets  28   d  comprise upper and lower plies  66 ,  68 , respectively, joined together along intersecting seams  70 . As shown in  FIG. 11A , the spaced seams  70  intersect each other at intersections  72  and assume a checkerboard type of pattern. Some of the seams  70  extend transversely or from side-to-side while other seams  70  extend longitudinally or from head-to-foot. 
         [0040]    One of ordinary skill in the art will readily recognize that the alternative embodiments of the mattress topper shown herein are exemplary only of a wide variety of alternative configurations that are readily possible within the scope of this invention. 
         [0041]    From the above disclosure of the general principles of the present invention, and the preceding detailed description of at least one preferred embodiment, those skilled in the art will readily comprehend the various modifications to which this invention is susceptible. Therefore, we desire to be limited only by the scope of the following claims and equivalents thereof.