Abstract:
A padded mattress cover for a mattress has a top panel with a first perimeter, a first rope attached to the top panel along the first perimeter, and a gusset attached to the first rope. A second rope is attached to the gusset opposite the first rope and a bottom panel with a second perimeter is attached to the second rope along the second perimeter, the bottom panel being opposed to the top panel to form an interior within the cover. A latex layer is positioned beneath the top panel and within the interior. A non-woven layer is positioned beneath the latex layer and within the interior. Finally, a plurality of puff balls are positioned between the non-woven layer and the bottom panel. The padded mattress cover may be positioned on a mattress with the bottom panel adjacent said mattress to cover said mattress.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    The present application is related to Chinese Patent Application No.______ filed Sep. 25, 2009, the disclosure of which is hereby incorporated by reference herein. 
       BACKGROUND OF THE INVENTION 
       [0002]    Padded mattress covers are a common part of the under coverings on which bed linens are placed or fitted. Such mattress covers were conventionally relatively thin and were used solely to protect the mattress. In recent years, however, mattress covers have been adopted include thicker padding to increase user comfort and extend the life of the underlying mattress. Another reason is to provide isolation and insulation between the mattress and the user. 
         [0003]    Conventional fill materials for such mattress covers vary from polyester to down, or even trapped air. These fillers are lightweight and have exceptional air-trapping capacity that creates an insulation barrier within the padded mattress cover&#39;s shell that contains the filler. The height of this insulation barrier, commonly referred to as loft, is important. Generally, the thicker the fill, or the greater the loft, the greater the insulation and comfort factor. 
         [0004]    One downside of using polyester, down, or even air fill is that none of these materials is hypo-allergenic, anti-microbial, or dust mite resistant. Thus, for extended use as bedding materials they are not necessarily the most ideal products. Lofty materials also require greater sized packaging, which negatively affects available shelf space and transport of the covers. 
         [0005]    It would therefore be advantageous to provide a padded mattress cover that includes the insulating and comfort qualities of a lofty polyester or down, while needing less loft producing materials, while also being hypo-allergenic, anti-microbial, or dust mite resistant. 
       SUMMARY OF THE INVENTION 
       [0006]    To fulfill this need, and in accordance with one aspect of the present invention, there is provided a padded mattress cover for covering a mattress. The padded mattress cover has a top panel with a first perimeter, a first rope attached to the top panel along the first perimeter, a gusset attached to the first rope, a second rope attached to the gusset opposite the first rope, and a bottom panel having a second perimeter, the bottom panel being attached to the second rope along the second perimeter. The bottom panel is opposed to the top panel to form an interior within the top panel, the gusset, and the bottom panel. The padded mattress cover also has a latex layer positioned beneath the top panel and within the interior, a non-woven layer positioned beneath the latex layer and within the interior, and a plurality of puff balls positioned between the non-woven layer and the bottom panel. The padded mattress cover may be positioned on a mattress with the bottom panel adjacent the mattress to cover the mattress. 
         [0007]    The latex layer may comprise approximately 40-60% of the interior with the puff balls comprising approximately the remainder. 
         [0008]    The latex layer and the non-woven layer may be sewn to the top panel within the perimeter. 
         [0009]    The cover may further comprise a skirt extending from the second rope. 
         [0010]    The puff balls may be formed from latex. 
         [0011]    The padded mattress cover may be hypo-allergenic, anti-microbial, or dust mite resistant. 
         [0012]    The top panel, latex layer, and non-woven layer may be breathable. 
         [0013]    The padded mattress cover may further comprise a second non-woven layer adjacent the first non-woven layer. If so provided, the latex layer and the non-woven layers may be sewn to the first rope and the second rope. 
         [0014]    The latex layer may be an open cell latex. 
         [0015]    In accordance with a further aspect of the present invention, a padded mattress cover comprises a top panel, a bottom panel secured to the top panel around a perimeter thereof, and a layer of latex positioned between the top and bottom panels. 
         [0016]    The layer of latex may be open cell latex. 
         [0017]    The cover may further comprise at least one non-woven layer, the at least one non-woven layer positioned between the latex layer and the bottom panel. 
         [0018]    The cover may further comprise a gusset connected between the perimeters of the top panel and the bottom panel, the gusset forming an available loft, the layer of latex at least partially filling the available loft. If so provided, the cover may further comprise a first rope connected between the top panel and the gusset, wherein the latex layer is sewn to the first rope. The cover may further comprise a second rope connected between the gusset and the bottom panel, wherein the latex layer is sewn to the first rope and the second rope. 
         [0019]    The cover may further comprise a plurality of puff balls between the latex layer and the bottom panel. If so provided, the cover may also include a non-woven layer between the latex layer and the puff balls, wherein the puff balls are at least partially secured in a plurality of chambers formed by the non-woven layer and the bottom panel. The puff balls may comprise approximately 40-60% of the inner volume of the padded mattress cover and the latex layer may comprise approximately the remaining inner volume. 
         [0020]    The latex layer may be approximately ¼″ thick. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0021]    Other advantages and features of the invention are described with reference to exemplary embodiments, which are intended to explain and not to limit the invention, and are illustrated in the drawings in which: 
           [0022]      FIG. 1  is a partial, perspective view of an exemplary padded mattress cover in accordance with the present invention; 
           [0023]      FIG. 2  is a partial cutaway view of the padded mattress cover of  FIG. 1 , taken along section line A-A. 
       
    
    
     DETAILED DESCRIPTION 
       [0024]    The following discussion describes, in detail, various aspects and embodiments of the present invention. This discussion should not be construed as limiting the invention to those particular aspects or embodiments. Rather, practitioners skilled in the art will recognize numerous other aspects and embodiments as well, which are within the scope of the present invention. 
         [0025]    In describing the preferred embodiments of the present invention illustrated in the drawings, specific terminology will be used for the sake of clarity. However, the present invention is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes all technical equivalents that operate in a similar manner to accomplish a similar purpose. 
         [0026]    For purposes of explanation, the invention is specifically described herein with regard to padded mattress covers. However, it is to be understood that any number of bedding material articles may utilize the same teachings, for example mattress toppers that are formed integrally with a mattress. 
         [0027]    The exemplary embodiment of the present invention shown in  FIGS. 1 and 2  comprises a padded mattress cover  10  (also referred to as a mattress pad  10 ), which can be removably disposed onto a mattress or other bed equipment. Advantages of being removable include the ability to store and/or clean the padded mattress cover as well as allow the mattress to be flipped over during its usable life, while still retaining a padded mattress look and feel. Another advantage is that the padded mattress cover can be used on more than one mattress of the same or similar size. 
         [0028]    As shown in  FIGS. 1 and 2 , the preferred padded mattress cover  10  comprises a padded portion  12  and a skirt  14 . The padded portion  12  comprises a top panel  16 , a bottom panel  18  (see  FIG. 2 ) and a gusset  20  secured between the top panel and bottom panel. As known in the art, the gusset  20  provides room for various layers of internal materials, described below. Each of the top and bottom panels  16 ,  18 , and the gusset  20  may be manufactured from any type of suitable material such as any conventional bed clothing cloth like cotton, wool, silk, polyester, or any combination of the aforementioned materials. Other materials will also be readily apparent to one skilled in the art. In a most preferred embodiment, the top panel  16  is formed from 100% cotton and the bottom panel  18  is formed from 100% polyester. 
         [0029]    Around the perimeter junction between the top panel  16  and the gusset  20 , and then again between the gusset  20  and the bottom panel  18 , are optionally sewn in two ropes  22   a ,  22   b . Although these ropes  22   a ,  22   b  function to help bolster the connection between the top panel  16 , gusset  20 , and bottom panel  18 , they are primarily provided for aesthetic purposes and may be manufactured from satin or silk-like materials, in addition to conventional materials listed above, such as wool, cotton, and polyester. It will be appreciated that the bottom rope  22   b  is also utilized to help support the skirt  14 . In other embodiments, ropes  22   a ,  22   b  may not be provided and the remaining elements, may be sewn directly to themselves. In preferred embodiments, the ropes  22   a ,  22   b  are formed from ⅛″ satin cord. 
         [0030]    In the embodiment shown in  FIGS. 1 and 2 , the skirt  14  is a conventional skirt and includes an elastic band  24  at its inside end  26 . The skirt  14  may be sized to accommodate various height mattresses, and includes an exposed side  28  and an underside  30 , the underside extending beneath a mattress M. Like the panels  16 ,  18 , the skirt  14  may be manufactured from a variety of materials including cotton, wool, silk, polyester, or any combination of the aforementioned materials. In a preferred embodiment, the skirt  14  is formed from 95% polyester and 5% spandex having 2-way stretch capabilities. 
         [0031]    Within the gusseted area of the padded portion  12 , the mattress pad  10  comprises several layers. The initial layer, or upper most layer, has already been discussed, and is the top panel  16 . Beneath the top panel  16  is provided a layer of latex  32 . The latex layer  32  is preferably configured as open cell foam which is breathable, and may be approximately ⅛″ to ½″ inch thick. Other thicknesses may also be utilized, for example 1/16″ through 1″ or more. In a preferred embodiment, the latex layer  32  is ¼″ thick. 
         [0032]    Although it need not be, the latex layer  32  is preferably sewn directly to both of the ropes  22   a ,  22   b  with stitching  34 . This configuration strengthens the connection of the latex layer  32  to the remainder of the padded mattress  10 , and also helps to define the loft of the padded portion  12  for structural and aesthetic purposes. In this regard, the latex layer helps to keep the gusset fully extended and presents a nicely finished overall look to the padded mattress cover. 
         [0033]    Preferably, immediately below the latex layer  32  are two layers of non-woven fabric, formed as an upper non-woven layer  36  and a lower non-woven layer  38 . Each of these layers is also preferably sewn to both ropes  22   a ,  22   b . These non-woven layers  36 ,  38  are typically breathable to permit air to pass, and are preferably formed from 100% polyester, although other materials such as cotton, silk, wool, or the like may be utilized. 
         [0034]    It will be appreciated that the latex layer  32 , upper non-woven layer  36 , and lower non-woven layer  38  are preferably therefore secured to the padded mattress  10  at least generally at their perimeters, where they meet the ropes  22   a ,  22   b . In preferred embodiments, they may also be sewn to the top panel  16  by quilting or other stitching means  42 . However, in other embodiments they may not be sewn and instead are permitted to float relative to the top layer  16 . Finally, in still further embodiments only the latex layer  36  or the latex layer and the upper non-woven layer  36  may be sewn to the top layer  16  by stitching  42 . 
         [0035]    Beneath the lower non-woven layer  38  is a layer of puff balls  40 . In preferred embodiments, the puff ball layer is comprised of a series of small puff-blown polyester balls  41 . Such fiberfill is known in the art to be resilient, fluffable, and shapeable, much like natural down. This puff ball layer is preferably filled such that it represents 40% of the inner volume of the padded portion  12 , with the latex layer  32  comprising roughly the remaining 60%, or vice versa. In other embodiments, the percentage ranges can vary from virtually zero to 100% for either element, but generally a range from 40% to 60% for either element is preferred. In other embodiments, the puff balls  41  themselves may be configured from latex, such as puff-blown latex. 
         [0036]    Beneath the puff ball layer  40  is the bottom panel  18 . As discussed above, the bottom panel is typically only sewn to the lower-most rope  22   b . Likewise, it is also not typically secured to any other element except at this outside perimeter connection, thus permitting the inner portions, particularly the puff ball layer  40 , to float relative to the other elements. In still further embodiments, the bottom panel  18  may be sewn to at least the lower non-woven layer  38  in a manner to create open chambers (not shown). Such open chambers may comprise a large percentage of closed stitching, which prevents the puff balls  41  from moving from one chamber to an adjacent chamber. But, the chambers may also be partially opened, to permit some level of migration. Typically, the openings only represent approximately 5-20% of the overall channel perimeter to limit too much migration, while still permitting some. Such openings also permit a user to manually move puff balls  41  from one chamber to another if desired. 
         [0037]    In use, a user will typically lay on the padded mattress cover after the cover is placed on a mattress. By positioning the latex layer between the user and the puff ball layer, the mattress pad may be provided with a lesser quantity of puff ball while still providing equivalent loft, insulation, and comfort level characteristics as a conventional padded mattress cover with no latex layer. This is due in part because of the structural qualities of the latex foam and its ability to mold to a user&#39;s body while being structurally resilient. This also permits an equivalently performing padded mattress cover to have a lesser volume than a conventional mattress cover, which is beneficial for transport and reduced shelf space. 
         [0038]    Moreover, the latex layer permits the mattress pad to remain air permeable, such that the mattress pad can breath. Latex itself is hypo-allergenic, anti-microbial, and dust mite resistant. However, the breathability also helps to contribute to the complete mattress pad being hypo-allergenic, anti-microbial, and dust mite resistant. In addition, the breathability of latex keeps the user warm in the winter and cool in the summer. These features could not be achieved if conventional rubber materials were utilized in lieu of latex, as such materials are air-tight and are not hypo-allergenic, anti-microbial, and dust mite resistant. 
         [0039]    While the exemplary embodiment of the mattress pad  10  has been described with a single latex layer  32 , it will be appreciated that multiple latex layers  32  may also be provided. These layers may directly abut each other or there may be other layers in between, such non-woven layers or additional puff ball layers. Additionally, it will be appreciated that although the mattress pad  10  has been described with multiple non-woven layers  36 ,  38 , it will be appreciated that the mattress pad may include no non-woven layers, or more than two non-woven layers. 
         [0040]    Likewise, a skirt  14  may also not be provided. In such embodiments, the mattress pad  10  may be configured to rest directly on the mattress M without additional support. Alternatively, support systems such as conventional straps and the like may be utilized to prevent relative movement between the mattress pad  10  and the mattress M. 
         [0041]    Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the appended claims.