Mattress, box springs fabric

A body support element such as a mattress, box springs or the like that exhibits non-slip qualities as to a further item freely supported thereon. A ticking fabric covers at least an upper surface of the element includes a base fabric having pairs of yarns laid in atop said base fabric and secured thereto, the lay in yarns following non-linear paths. The yarns of each pair preferably follow mirror image paths to the opposite yarn of the pair. Processes for producing the ticking fabric and finishing same are also included.

BACKGROUND OF THE INVENTION 
The present invention relates to a mattress, box springs or other body 
supporting element having a slip resistant covering thereover. 
Mattresses for use in conventional fashion, i.e., as support for a human 
body in a supine position basically include a framework or border of some 
sort, a resilient support means located within the border which is 
generally a series of interrelated coil spring formations, a foam 
structure, a water cell, or the like to properly support an individual 
residing thereon, and a cover material that generally fully encloses the 
support means and the frame. Such cover material is conventionally 
referred to as mattress ticking. Furthermore, under normal circumstances, 
a mattress is sold in conjunction with a box springs or other support 
member which is locateable therebeneath and which likewise include a 
support means by way of an interrelated spring arrangment and an 
appropriate cover. When the box springs and mattress are sold as a set, 
the ticking fabric that is applied to the mattress is likewise utilized as 
a cover fabric for the box springs for the sake of aesthetic continuity. 
Ticking fabrics throughout the years have included various and sundry 
materials with certain basic criteria being considered in the manufacture 
of same. Particularly, the fabric should have adequate strength and cover 
to enclose the contents of the mattress or the box springs and support the 
anticipated human weight, should preclude against creation of tactile 
impressions of the support means on the individual residing on the 
mattress, should be aesthetically pleasing, should be economical, and 
peferably should be treated for water and stain resistance. The ticking 
fabrics may include a padding layer to preclude tactile transmission of 
the support means therethrough or conversely, a separate layer may be 
provided between the support means and the ticking fabric. Historically, 
as mentioned above, various and sundry types of fabrics have been utilized 
for mattress ticking, and economics has played a major role in decisions 
as to the type fabric to be employed. By way of example, for many years, 
conventional cotton fabrics were woven with a striped design that became 
symbolic of a ticking fabric look. More recently, due to the increase in 
price of cotton as well as the availability of the manmade fibers, there 
has been a tendency to move away from the cotton ticking and to utilize 
fabrics that are manufactured wholly from manmade fibers or from blends of 
cotton and manmade fibers. At the same time, such fabrics have customarily 
been coated with materials to improve the optical qualities of the fabric, 
to upgrade cover of the fabric and to provide a suitable substrate for the 
printing of aesthetic designs thereon. 
Particularly insofar as fabrics including manmade yarns or fibers are 
concerned, the surface of the ticking fabrics offers less frictional 
resistance than a 100% cotton fabric in a plane transverse to the fabric 
surface. Likewise with cotton fabrics, however, there is a tendency for 
sheets or other bed coverings, unless they are form fitted to slide across 
the surface of the fabric, resulting in disarray of the bed, discomfort to 
one sleeping thereon, and inconvenience to the person making and/or 
remaking the bed. Further, and very importantly there is a greater 
tendency of a mattress lying atop a bed springs or other support to move 
relative to the box springs. Such occurs in retail outlets for the goods 
where bed covering is not applied and in the home as well. 
In the present day market, conventional mattress ticking fabrics are woven 
polyester cotton fabrics in which the yarns making up the fabric are 
blends of cotton and polyester fibers, woven jacquard fabrics, and knit 
fabrics, such as tricots. The woven polyester cotton fabrics and the knit 
fabrics are normally overprinted with an aesthetic design while the woven 
jacquard fabrics include aesthetic designs that were produced in the 
fabric during weaving. The woven jacquard fabrics while being more 
substantial in hand and perhaps in aesthetic quality are significantly 
more expensive than the woven polyester cotton or tricot ticking fabrics, 
such that jacquards are normally limited in use to more expensive 
mattresses. Standard woven polyester cotton and tricot fabrics are 
conventioanlly uutilized in maufacture of the lesser cost goods. With all 
three types, however, as well as other types presently available, the 
problem of slippage across the top surface of the mattress is present. 
Body supporting elements according to teachings of the 1present invention 
utilize a particular type fabric which overcomes the slippage problem 
while being capable of presenting an aesthetic quality similar to jacquard 
fabrics. In the context of the present invention, the instant ticking 
fabric may be utilized with one or more of the body supporting elements of 
a bed, and the term body supporting element is intended to refer to all 
such elements, as exemplified by mattress, water cells, box springs and 
the like. Particularly, fabrics according to the present invention include 
means to resist relative movement of a mattress relative to a box springs 
or other support on which the mattress freely resides without like 
restraints, of bed coverings across the upper surface of a mattress and 
the like. At the same time fabrics produced according to the present 
invention are capable of being back coated with polymeric foams and the 
like to achieve an overall fabric having acceptable or improved stiffness 
and hand quality. Likewise, fabrics utilized in conjunction with body 
supporting elements according to the present invention may be overprinted 
with a particular print pattern or conversely, include an aesthetic 
pattern knitted into the fabric at the time of manufacture. 
Insofar as present fabrics, per se, are concerned, yarns are located in a 
particular arrangement in spaced apart fashion across the upper surface of 
same, which yarns provide resistive forces against relative movement of an 
item freely resting thereatop or vice versa. The particular top yarns, 
which are laid in during fabric manufacture, follow non-linear paths, 
preferably in pairs with each yarn of a pair preferably following a mirror 
image path of the other yarn of the pair to provide the resistive forces 
referred to. Though there is known prior art which includes the provision 
of decorative yarns laid in during the production of a knit fabric in the 
longitudinal direction, and along non-linear paths, there is no fabric 
that is known to exist in which the particular lay in yarns are arranged 
for the particular purposes of the present invention. 
Additionally, the industry has historically been unable to back coat 
fabrics containing acetate yarns with success, and in fact, both the fiber 
producers and the chemical suppliers recommend against same. The inability 
of success of such a coating operation results from the elevated 
temperatures involved in the application and curing of the coating 
materials, which are adequate to cause significant degradation of the 
acetate yarns. Again, however, with the fabrics according to the present 
invention, same can be successfully back coated with polymeric foams under 
normal process conditions without experiencing any apparent degradation of 
the acetate yarns. 
SUMMARY OF THE INVENTION 
It is an object of the present inventin to provide an improved body 
supporting element, the upper surface of which is characterized as having 
non-slip properties. 
Another object of the present invention is to provide an improved body 
supporting element which utilizes a ticking fabric that has a high 
friction outer surface. 
Yet another object of the present invention is to provide an improved body 
supporting element which utilizes a ticking fabric that approaches the 
qualities and characteristics of a woven jacquard fabric at a more 
economical price, and which has improved surface characteristics. 
Still further, another object of the present invention is to provide an 
improved decorative fabric that exhibits a high friction outer surface. 
Yet another object of the present invention is to provide an improved knit 
ticking fabric having non-slip qualities along its upper surface. 
Still further, another object of the present invention is to provide an 
improved fabric that includes acetate yarns, which fabric may be 
successfully coated at temperatures above the degradation point of the 
acetate yarns, but without any apparent degradation of same. 
Generally speaking, the body supporting element of the present invention 
that exhibits a non-slip outer surface comprises a conventional framework; 
support means associated with the framework; and a ticking fabric that is 
secured around the outer periphery of the element, said fabric comprising 
a base knit structure having adquate strength to support a human body and 
to enclose at least a portion of said element, said base knit structure 
having a plurality of first yarns laid atop same and secured thereto, said 
first top yarns residing above said base structure and following a 
non-linear path therealong, and second top yarns laid atop said base knit 
structure and being secured thereto, said second top yarns following a 
non-linear path along said fabric that produces a mirror image to said 
first top yarns, whereby said first and second yarns cooperate to produce 
a slip resistant surface. 
More specifically, the ticking fabrics used on body support elements 
according to teachings of the present invention include a plurality of 
pairs of lay in yarns that are introduced to the knitting machine 
longitudinally with respect to the fabric being produced. Bars to which 
the lay in yarns are fed are oscillated back and forth across the machine 
to deposit the lay in yarns along mirror image, non-linear paths. As the 
lay in yarns are introduced to the knitting machine, same are locked into 
the fabric by the knit stitches, while remaining above the upper surface 
of the base fabric. 
After the fabric leaves the knitting machine, according to a preferred 
embodiment, yarns of the base structure are tinted in a pad bath and the 
fabric is heat set at open width in a tenter frame. Thereafter, the heat 
set fabric is passed upside down beneath a coating head where a back 
coating composition, preferably a latex foam composition is applied to the 
underside of the fabric. The coated fabric is then passed through a curing 
oven where the latex foam is cured, after which the fabric passes around 
cooling cans and is taken up. Subsequently, if desired, the coated fabric 
may be passed through a printing operation where a predetermined aesthetic 
design is printed by roller printing or the like across an upper surface 
of same followed by drying and take up. Subsequent to the coating 
operation or printing, if employed, a protective fluorocarbon type 
chemical may be applied thereto, to impart water-resistat, stain 
resistant, or other characteristics, after which the fabric is further 
heat set at open width. The finally finished fabric may then be taken up 
for transport to the mattress manufacturer. 
With the pairs of upstanding surface yarns secured to the upper surface of 
the base fabric, items contacting the upstanding yarns encounter 
resistance to movement relative to the fabric in all directions. Bed 
coverings, for example, once placed on a mattress better remain in place 
than with a conventional mattress. In like fashion, the mattress per se is 
resistant to movement across an upper surface of a box springs or other 
support located therebeneath, and on which the mattress freely resides 
without restraints.

DESCRIPTION OF THE PREFERRED EMBODIMENTS 
Making reference to the Figures, preferred embodiments of the present 
invention will now be described in detail. FIG. 1 illustrates a body 
support element, e.g. a mattress generally indicated as 10 according to 
teachings of the present invention having a frame or border 20 surrounding 
the periphery of same with appropriate support means 30 received within 
frame or border 20 for providing resilient support to an individual 
sitting or lying thereon in a supine position. A ticking fabric of the 
present invention generally 40 is partially illustrated across the surface 
of mattress 10 with upstanding lay in yarns 45, 45' being partially 
illustrated thereon. Fabric 40 is preferably be located completely around 
mattress 10. 
As can be seen in FIGS. 1, 2 and 9, ticking fabric 40 has a knitted base 42 
with yarns 45, 45' being laid in on the knitting machine at the time of 
manufacture of the fabric along non-linear paths. Lay in yarns 45, 45' are 
secured within the knit stitches of the base structure 42 according to 
conventinal knitting techniques. As particularly shown in FIG. 2, each 
yarn 45, 45' follows a mirror image, non-linear path with respect to its 
opposite yarn, whereby as shown by the arrows, a frictional resistance 
from upstanding yarns 45, 45' will be produced in all directions. More 
particularly, with the non-linear mirror image arrangement as illustrated, 
movement of the mattress with respect to a support located therebeneath or 
a bed covering along any vector will encounter lay in yarns 45, 45' 
substantially normal thereto. 
FIG. 3 illustrates a further fabric embodiment according to teachings of 
the present invention where a plurality of pairs of lay in yarns 145, 145' 
are arranged in pair groupings atop base fabric 142 with a space 146 
located between the various pair groupings in which no lay in yarns are 
secured to the base fabric. Accordingly, as can be seen from FIG. 3, it is 
not necessary that a continuum of non-linear lay in yarns 145, 145', etc. 
be located across the entire width of the fabric 140. Spaces 146 between 
the pair groupings may thus vary. It is only necessary, whatever grouping 
arrangment is employed, that the resistive forces are present in generally 
all directions, and that sufficient lay in yarns be present to 
cooperatively afford adequate resistive force against relative movement of 
a bed covering across a mattress; a mattress across a box springs, or the 
like. 
In order to further demonstrate particular types of fabrics that are 
suitable for use according to teachings of the present invention, an 
exemplary fabric design in particularly illustrated in FIG. 4. A plurality 
of yarns 41, such as 40 denier filament polyester, are fed to the first 
bar of a raschel warp knitting machine (not shown), with bar 1 being 
interrelated with the knitting needles to produce a plurality of chain 
stitches 41'. Bars 2 and 3 of the knitting machine receive the lay in 
yarns 45 45' and are contacted by cams or other suitable means to follow 
the non-linear mirror image paths along the length of the fabric. A 
further knitting yarn 43, for example, 75 or 100 denier bright acetate 
staple yarn was fed to bar 4 and serves as a crossover yarn which, when 
incorporated with the chain stitches of bar 1 forms the base fabric 
structure 42. As illustrated in the design in FIG. 4, the crossover yarns 
43 lap around a first needle, thereafter move diagonally forward one 
needle position and across at least one needle row, wrapping around a 
diagonally opposite needle and returning diagonally to the original needle 
row, again, however, moving upwardly one needle position. Such occurs 
across the width of the fabric and provides the cover factor for base 
fabric structure 42. Lay in yarns 45, 45' as they cross needle rows, are 
interengaged with the chain stitches to be fully integrated into the 
fabric structure. Due to the fineness of the chain stitch yarns, however, 
the lay in yarns appear to be resting unattached or floating along the top 
surface of the ticking fabric. 
As mentioned hereinbefore, it may be desirable to back coat fabrics 
according to teachings of the present invention to improve the handle 
and/or stiffness of the fabric. Making reference to FIGS. 5-8, certain 
finishing processes that may be desirable for fabrics according to the 
present invention will be generally described. Each of these particular 
processes is well known and well established in the art, such that a 
general description of each should suffice to enable one skilled in the 
art to practice the invention. 
Subsequent to removal of the fabric from the knitting machine, the fabric F 
is passed through a pad bath 50 that contains a dyestuff composition 
appropriate for tinting the base fabric structure 42, while avoiding 
adverse dye effect on the lay in yarns 45 45', if a contrast is desired 
(See FIG. 5). Such is permitted due to the particular tint compositions 
utilized, the short residence time in the pad bath, and the type of yarns 
employed. Subsequent to the pad bath 50, fabric F passes through a tenter 
frame 52 where the fabric is maintained at full width under temperature 
conditions adequate to heat set the synthetic yarns employed in the 
fabric, generally in a range of from about 350.degree. to about 
375.degree. F., and is thereafter taken up on conventional take up means 
54 in roll form. Referring to FIG. 6, fabric F is fed upside down beneath 
a coater head 60 where a quantity of a coating composition C such as a 
latex foam composition is applied to the underside of the fabric (See also 
FIG. 9). Coater head 60 is in essence a doctor blade that controls the 
amount of application of composition C to the fabric from a puddle of 
same. Subsequent to the coating head 60, the coated fabric CF then passes 
through a suitable curing oven 62 where the latex is cured and foamed at 
temperatures generally also in a range of from about 350.degree. to about 
375.degree. F. Likewise, however, other back coating compositions as 
conventionally employed in the art may be applied at coating head 60. 
Subsequent to curing oven 62, coated fabric CF is cooled as by one or more 
cooling cans 64 and is then taken up in roll form on a conventional take 
up means 66. 
If desired, subsequent to coating of the fabric, as illustrated in FIG. 7, 
the coated fabric may be passed through an appropriate printing range, 
whereby roller or other type printing means schematically indicated as 70 
print a particular design or motif onto an upper surface of coated fabric 
CF, purely for enhancement of the aesthetic effects of fabric CF. 
Subsequent to the print station 70, the printed fabric CF passes through 
an appropriate oven 72 where the fabric is dried, after which fabric CF is 
taken up in roll form on a conventional take up means 74. As a final step 
in the processing of fabric according to teachings of the present 
invention, the coated fabric CF may be passed through yet a further pad 
bath 80 where appropriate fluorocarbon or other type chemical compositions 
may be applied thereto as a protective coating for the fabric, followed by 
a further heat set operation in a tenter frame 82 and take up on roll 
means 84. The coated fabric CF may thus have a water resistant, stain 
resistant, or other type surface quality as dictated by the particular end 
use imparted thereto. 
It is generally accepted in the art, both as from a chemical manufacturer's 
standpoint and a fiber producer's standpoint that acetate type yarns may 
not be back coated as illustrated above. Particularly, at temperatures in 
a range of 350.degree. and 370.degree. F. to which the fabrics according 
to the present invention are subjected in the four process steps outlined 
above, serious degradation of the acetate yarn normally occurs. In fact, 
under normal conditions, when an acetate yarn is subjected to a 
temperature in a range of about 370.degree. F. for a short period of time, 
the acetate yarn becomes quite brittle, thus negating any worthwhile use 
of a fabric embodying same. Strangely enough, however, according to the 
present invention where the acetate yarn is preferred due to its cost and 
sheen to provide the cover for the base fabric structure, after heat 
setting same at a temperature of around 370.degree. F., and coating the 
fabric as outlined above, no degradation of the acetate is apparent. 
While certain design configuration and stitch constructions have been 
described above for fabrics according to the present invention suitable 
for ticking having a non-slip upper surface, obviously other fabric 
constructions and other design variations of the lay in yarns may be 
utilized. In like fashion, the particular yarns listed in describing a 
preferred fabric according to the present invention should not be 
considered as limiting, and any other type of yarn that would be suitable 
for such end use and to the fabric manufacturing process may be utilized. 
Having described the present invention in detail, it is obvious that one 
skilled in the art will be able to make variations and modifications 
thereto without departing from the scope of the invention. Accordingly, 
the scope of the present invention should be determined only by the claims 
appended hereto.