Abstract:
The present invention relates to a cover for a mattress and bed deck. More particularly, the present invention relates to a mattress and bed deck cover for an adjustable bed that reduces the exposure of the mattress and bed deck to unsanitary conditions.

Description:
This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/270,739, entitled MATTRESS AND BED DECK COVER, to Bruce M. Rippe, David J. Ulrich, Catherine M. Wagner, Douglas E. Borgman, and Bernard F. Voegele, filed Jul. 13, 2009 and incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     (a) Field of the Invention 
     The present invention relates to a cover for a mattress and bed deck. More particularly, the present invention relates to a mattress and bed deck cover for an adjustable bed that reduces the exposure of the mattress and bed deck to unsanitary conditions. 
     (b) Description of the Prior Art 
     Mattress covers are commonly used to protect mattresses from staining, soiling, or other results of contact with unsanitary conditions. The need for effective mattress covers is greater in a healthcare setting, where contact with large scale contaminants, such as blood or waste products, and small scale contaminants, such as bacteria or fungi, is a daily occurrence. Mattress covers must be cleaned on a regular basis to maintain a sanitary environment. 
     Mattresses are supported by bed decks. Bed decks may come into contact with the same unsanitary conditions as mattresses and mattress covers. For example, waste produced by a patient may flow off the mattress or mattress cover and accumulate on the supporting bed deck. Under current techniques, the cumbersome mattress must be manually raised from the bed deck, the bed deck cleaned by hand using a germicidal solution, and the mattress replaced atop the bed deck. However, hospital workers may neglect to clean the bed deck, or may not fully clean the entire surface of the bed deck. Furthermore, manual cleaning may not be sufficient to eliminate bacteria embedded in the bed deck or kill fungal spores. Any remaining contamination may be passed from the bed deck to clean mattress covers or bed sheets, from which the contaminants may contact a patient. 
     A need exists for a removable cover that protects both mattresses and bed decks from unsanitary conditions and is capable of being laundered. This need is complicated in a healthcare environment, where mattresses and bed decks are incorporated into adjustable beds. Adjustable beds used in healthcare settings include bed decks and mattress which can be raised, lowered, and articulated into various configurations. A need exists for a removable cover for the mattress and bed deck of an adjustable bed that is capable of protecting and remaining attached to the mattress and bed deck while the adjustable bed adopts different configurations. 
     SUMMARY OF THE INVENTION 
     The aforementioned problems have been solved in the present invention, which provides a mattress and bed deck cover. More particularly, the present invention relates to a mattress and bed deck cover for an adjustable bed that reduces the exposure of the mattress and bed deck to unsanitary conditions. 
     Conventional bedding utilizes a fitted sheet that encapsulates the top and sides of a mattress, and a flat sheet and one or more blankets that are tucked into the space between the mattress and the supporting bed deck or box spring. One difficulty with using a single cover to protect both the mattress and the bed deck is that access to the space between the mattress and bed deck would be lost and bedding material could not be tucked into that space. The present invention solves this problem by including a channel at the head end of the cover, whereby a fitted sheet may be wrapped around the head end of the mattress, and a channel at the foot end of the cover, whereby a fitted sheet may be wrapped around the foot end of the mattress and a flat sheet and blankets may be tucked between the mattress and bed deck. 
     Adjustable beds, as used in hospitals and other healthcare settings, can be raised, lowered, and adjusted into various configurations. The present invention is capable of remaining in position on the mattress and bed deck while the adjustable bed adopts different configurations. While the bed is positioned horizontally, the mattress and bed deck cover fits tautly over the bed. A taut cover eliminates folds and gathers in which waste may accumulate and which may cause pressure ulcers. Furthermore, the present invention may include at least one flap to cover specific areas of the adjustable bed, such as the pivot points, which may be more susceptible to contamination. 
     Adjustable beds, as used in hospitals and other healthcare settings, may incorporate devices or controls, such as, for example, emergency release handles used to lower the head end of the adjustable bed as required to administer CPR. Access to these devices or controls cannot be restricted by the mattress and bed deck cover. The present inventions solves this problem by providing a sufficient number of cutouts to grant access to devices incorporated into the bed deck, while still protecting the bed deck from contamination and remaining securely attached to the mattress and bed deck. Cutouts may also be included to allow the mattress and bed deck cover to fit around bed rails, handles, other structural features of adjustable beds. 
     Certain inorganic agents, such as metal ions, are known to have antimicrobial and antifungal activity. Silver is known as a broad spectrum antibiotic with minimal health concerns. Copper is known to have antifungal activity and a synergistic effect with silver against bacteria. Zinc has weak antimicrobial activity and the ability to moderate the release of silver from a carrier. While there is a low frequency of bacteria developing resistance to silver, exposure to sub-lethal concentrations of silver may increase the chance of resistance development. 
     The present invention combines the antimicrobial and antifungal properties of metal ions with the need for more hygienic surfaces in bedding. In this embodiment, the present invention relates to the incorporation of metal ions into a film coating applied to a mattress and bed deck cover. More particularly, the present invention relates to a mattress and bed deck cover coated with a film coating material incorporating soluble glass carriers containing silver. A particular advantage of this embodiment of the present invention over surface treatment of bedding material with antimicrobial agents is that metal ions are not released into the environment, but kill on contact. By providing a substantially nonleaching film coating, metal ions are not released into the environment, reducing the risk of bacteria developing resistance due to exposure of sub-lethal concentrations of metal ions. Thus the present invention provides the antimicrobial effectiveness of metal ions while minimizing the chances of creating bacterial strains resistant to the antimicrobial activity of metal ions. Another particular advantage of this embodiment is that incorporation of antimicrobial and antifungal properties into the present invention reduces odors. 
     The mattress and bed deck cover is designed to be laundered using U.S. Center for Disease Control-approved healthcare laundering techniques, e.g., washing with detergent in water at a temperature greater or equal to 160° F. (71° C.) for at least 25 minutes. Conventional mattress covers are manufactured using fabric welds to prevent fluids from wicking through the cover to the mattress. However, standard fabric welds tend to break during repeated laundering cycles. In addition, standard healthcare laundering techniques may not be sufficiently intense to eliminate bacteria embedded in a conventional mattress cover. In the present invention high strength welds are used which are capable of withstanding the agitation and high temperature of the laundering process. Furthermore, the antimicrobial film coating of the cover kills bacteria and prevents them from becoming embedded in the cover. Therefore, a standard healthcare laundering process is sufficiently intense to decontaminate the present invention, whereas it would not be sufficient to decontaminate a cover without such a film coating. 
     In one embodiment, the present invention is a mattress and bed deck cover, the cover comprising: a top surface; a head end descending from the top surface; a foot end descending from the top surface and opposing the head end; a pair of opposing sides descending from the top surface and substantially perpendicular to the head end and the foot end and connected thereto; means for removably fixing the cover in relation to a mattress and a bed deck; a head end channel extending the width of the head end and a portion of the length of the sides; and a foot end channel extending the width of the foot end and a portion of the length of the sides; wherein the cover is sized to enclose a mattress and at least a portion of a bed deck, with the head end channel and the foot end channel oriented to interpose a portion of the mattress and the bed deck. In this embodiment, the cover may further comprise at least one cutout corresponding to the shape and location of at least one device attached to the bed deck. The cover may also comprise at least one flap descending from at least one of the pair of sides and removably attachable to a bed incorporating the bed deck. In this embodiment, the cover is constructed of a liquid-impermeable, multi-directional stretch fabric including a substantially nonleaching antimicrobial film coating. The cover may incorporate an agent with antimicrobial and/or antifungal properties, such as an antimicrobial metal, more specifically, silver ions contained within glass carriers. 
     In a further embodiment, the present invention is a mattress and bed deck cover comprising a top surface; a head end descending from the top surface; a foot end descending from the top surface and opposing the head end; a pair of opposing sides descending from the top surface and substantially perpendicular to the head end and the foot end and connected thereto; at least one elastic band; a head end channel extending the width of the head end and a portion of the length of the sides; and a foot end channel extending the width of the foot end and a portion of the length of the sides; wherein the cover is sized to enclose a mattress and at least a portion of a bed deck, with the head end channel and the foot end channel oriented to interpose a portion of the mattress and the bed deck. In this embodiment, the elastic band is attached to the sides of the cover for drawing the cover beneath the bed deck for retention. The cover also includes at least one magnet and at least one hook for removably attaching the cover to the bed deck. The cover further comprises at least one strap, the at least one elastic band and the at least one strap for cooperatively drawing the cover beneath the bed deck for retention. In this embodiment, the cover further comprises a substantially nonleaching antimicrobial film coating. The cover also comprises at least one flap descending from at least one of the pair of opposing sides and removably attachable to a bed incorporating the bed deck, the flaps each including a magnet for removably attaching the flap to the bed. In this embodiment, the cover also includes at least one cutout corresponding to the location and shape of at least one device attached to the bed deck. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       A better understanding of the present invention will be had upon reference to the following description in conjunction with the accompanying drawing, wherein: 
         FIG. 1A  depicts a foot end perspective view of an adjustable bed and a mattress; 
         FIG. 1B  depicts a foot end perspective view of an adjustable bed and a first embodiment of a mattress and bed deck cover; 
         FIG. 2A  depicts a bottom perspective view of the first embodiment of a mattress and bed deck cover; 
         FIG. 2B  depicts a detail view of the bottom perspective view of the first embodiment of a mattress and bed deck cover; 
         FIG. 3  depicts a hidden line head end perspective view of the first embodiment of a mattress and bed deck cover; 
         FIG. 4  depicts a pattern layout for the first embodiment of a mattress and bed deck cover; 
         FIG. 5A  depicts a hidden line bottom perspective view of a second embodiment of a mattress and bed deck cover; 
         FIG. 5B  depicts a detail view of a hidden line bottom perspective view of the second embodiment of a mattress and bed deck cover; and 
         FIG. 5C  depicts a detail view of a hidden line bottom perspective view of the second embodiment of a mattress and bed deck cover. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       FIGS. 1-3  depict a first embodiment of a mattress and bed deck cover. As shown in  FIG. 1A , a mattress  10  includes a mattress top  12 , mattress sides  14 , and mattress bottom  16 . An adjustable bed  18  incorporates a bed deck  20  which supports and underlies the mattress  10 . The bed deck  20  includes a bed deck top  22 , bed deck sides  24 , and bed deck bottom  26 . The bed deck  20  also includes at least one pivot point  28  about which the bed deck  20  and mattress  10  may be articulated. As shown in  FIG. 1B , the mattress and bed deck cover  30  includes a top surface  32 , a head end  34  descending from the top surface  32 , a foot end  36  descending from the top surface  32  and opposing the head end  34 , and a pair of opposing sides  38  descending from the top surface  32  and substantially perpendicular to the head end  34  and the foot end  36  and connected thereto. The cover  30  may enclose at least the mattress top  12 , mattress sides  14 , and at least a portion of the mattress bottom  16 , and at least a portion of the bed deck top  22  and bed deck sides  24 . A person lying on the cover  30 , mattress  10 , and bed deck  20  preferably orients his or her head towards the head end  34  and his or her feet towards the foot end  36 . 
     The mattress and bed deck cover  30  is preferably constructed of a liquid-impermeable fabric with a film coating. In a preferred embodiment, the fabric is a multi-directional stretch polyester fabric with welded or sealed seams and corners. In this embodiment, the mattress and bed deck cover  30  is suitable for disinfection using healthcare laundering techniques. As shown in  FIGS. 2A and 2B , the mattress and bed deck cover  30  includes an inner surface  40 , which contacts the mattress  10  and bed deck  20 , and an outer surface  42 , which is exposed to the environment. In a preferred embodiment, the film coating is polyurethane and is only present on the outer surface  42 . The film coating preferably incorporates an agent with antimicrobial and/or antifungal properties such as, for example, antimicrobial metal. In a preferred embodiment, the film coating contains borophosphosilicate glass carriers containing silver ions. In this preferred embodiment, the film coating provides the cover  30  with a substantially nonleaching antimicrobial film coating. 
     The mattress and bed deck cover  30  includes means for removably fixing the cover  30  in relation to the mattress  10  and bed deck  20 . In one embodiment, the means for removably fixing the cover  30  is at least one elastic band. In the first embodiment depicted in  FIGS. 1-3 , the mattress and bed deck cover  30  includes a long elastic band  44 , a short elastic band  46 , and two straps  48  that collectively draw the mattress and bed deck cover  30  under the bed deck  20  for retention. In this embodiment, the cover  30  encloses at least a portion of the bed deck bottom  26 . As shown in  FIG. 2B , the long elastic band  44 , short elastic band  46 , and straps  48  are sewn or welded into the lower edge of the mattress and bed deck cover  30 . The short elastic band  46  located at the head end  34 , the two straps  48  located at the corners adjacent to the head end  34 , and the long elastic band  44  collectively define the opening of a cavity into which the mattress  10  is positioned. In an alternate embodiment, the mattress and bed deck cover  30  includes a single long elastic band  44  that defines the opening of the cavity. In this alternate embodiment, the mattress and bed deck cover  30  lacks straps  48  and the short elastic band  46 . In other embodiments, the mattress and bed deck cover  30  may employ hooks, fasteners, buttons, magnets, hook and loop attachments or other suitable means or combination of means for removably fixing the mattress and bed deck cover  30  in relation to the mattress  10  and bed deck  20 . 
     As shown in  FIG. 3 , the mattress and bed deck cover  30  includes a head end channel  50  located at the head end  34  of the cover  30  and extending the width of the head end  34  and a portion of the length of the sides  38 . The head end channel  50  permits a fitted sheet to wrap around the head end corners of the mattress  10 , while still preventing contaminants from contacting the mattress  10  and bed deck  20 . 
     The mattress and bed deck cover  30  also includes a foot end channel  52  located at the foot end  36  of the cover  30  and extending the width of the foot end  36  and a portion of the length of the sides  38 . The foot end channel  52  permits a fitted sheet to wrap around the foot end corners of the mattress  10  and permits flat sheets and blankets to be tucked between the mattress  10  and bed deck  20 , while still preventing contaminants from contacting the mattress  10  and bed deck  20 . 
     To cover locations which may be especially susceptible to contamination, such as pivot points  28 , the cover may include at least one flap  54 . Each flap  54  descends from the one of the sides  38  of the cover  30 . Each flap  54  includes attachment means to position the flap  54  to removably cover a location on the adjustable bed  18  and, as depicted in  FIG. 1B , remain in place as the bed  18  is articulated. In this first embodiment, a sealed pocket  56  is formed by placing two layers of polyurethane on the inner surface  40  of the flap  54 , inserting a magnet  58  between the layers, folding the edges of the flap  54  over the polyurethane layers, and welding the layers of polyurethane to the inner flap  54 . The magnet  58  allows the flap  54  to be removably attached to the bed deck  20  to provide extra coverage. Any other suitable attachment means for removably attaching the flap  54  to the bed  18 , such as, for example, hooks, buttons, fasteners, straps, or a plurality of magnets may be used. In a preferred embodiment (not shown), the pocket  56  is divided into two compartments each containing a magnet  58 . 
     The adjustable bed  18  may include at least one device, such as, for example bed rail, I.V. holder, trapeze adapter, or control for the bed  18 . One style of adjustable bed  18  includes two devices attached to the bed deck  20 , one located near each of the corners of the bed deck  20  adjacent to the head end  34 . These devices are emergency release handles used to quickly lower the head end  34  of the adjustable bed  18  to position a person lying on the adjustable bed  18  into a prone position, as required to administer CPR. To provide access to these devices, the first embodiment of a mattress and bed deck cover  30  includes at least one cutout  60 . More specifically, the cover  30  includes a cutout  60  at each of the corners of the mattress and bed deck cover  30  adjacent to the head end  34 . Each cutout  60  is sized to accept one of the devices, and thus corresponds to both the location and shape of the device. In this first embodiment, a strap  48  extends across cutout  60 , whereby strap  48  and cutout  60  combine to surround the device, providing access to device while maintaining coverage of the bed deck  20  and retention of the mattress and bed deck cover  30  on the mattress  10  and bed deck  20 . In other embodiments, the adjustable bed may include zero, one, or more than one devices. In these embodiments, the mattress and bed deck cover  30  includes one cutout  60  and one strap  48  per device. In an embodiment without any devices, the mattress and bed deck cover  30  may include a single long elastic band  44  as its means for removably fixing the cover  30  in relation to the mattress  10  and bed deck  20 . In this embodiment, the mattress and bed deck cover  30  lacks strap  48 , cutout  60 , and short elastic band  46 . 
     In the first embodiment, the bed deck  20  is 36 (91 cm) inches wide by 80 inches (203 cm) long by 1.5 inches (3.8 cm) high. In this embodiment, the mattress  10  is sized 36.5 inches (93 cm) wide by 80 inches (203 cm) long by 6 inches (15 cm) high. In this embodiment, the mattress and bed deck cover  30  is sized to snugly fit the mattress  10  and bed deck  20 . The mattress and bed deck cover  30  is about 80 inches (203 cm) in long, 36.5 inches (93 cm) wide and 7.375 inches (18.7 cm) high. 
     The first embodiment includes two cutouts  60  located at the corners of the cover  30  adjacent to the head end  34 . Each cutout  60  has overall slot dimensions of about 11.5 inches (29.2 cm), with 4.5 inches (11.4 cm) along the head end  34  and 7.0 inches (17.8 cm) along the sides  38  of the cover  30 . Each cutout is about 1.25 inches (3.18 cm) inches in height. Each strap  48  is about 9.5 inches (21.1 cm) long, about 1.0 inch (2.54 cm) wide, and constructed from woven nylon or polyester. In this embodiment the head end channel  50  has a length of about 4.0 inches (10.2 cm) and the foot end channel  52  has a length of about 15 inches (38.1 cm). The channels  50 ,  52  are located on the head end  34  and foot end  36 , respectively, at a height of about 4.125 inches (10.5 cm) from the top surface  32  of the cover  30 . The channels  50 ,  52  extend the full width of the cover  30 , and are about 0.625 inches (1.6 cm) in height. Each flap  54  is about 15.25 inches (38.7 cm) in length and narrows to about 6.5 inches (16.5 cm) in length at an angle of about 56 degrees as it descends from the side  38  of the cover  30 , forming an isosceles trapezoidal shape. Each flap  54  is about 6.5 inches (16.5 cm) in height. Two panels of polyurethane substantially corresponding to the size and shape of the flap  54  are welded to the inner surface  40  of each flap  54 , forming a sealed pocket  56  which encloses a magnet  58 . In a preferred embodiment (not shown), the pocket  56  is divided into two compartments each containing a magnet  58 . 
     This first embodiment describes a mattress and deck cover  30  sized to fit a particular mattress used in the healthcare industry. In other embodiments, the mattress and bed deck cover  30  may be sized to fit crib, twin/single, full/double, queen, king, or non-standard sized mattresses. 
       FIG. 4  depicts a pattern layout  62  of the first embodiment of a mattress and bed deck cover  30 . Cut lines  64  in the fabric are indicated by solid lines. Fold lines  66  are indicated by dashed lines. A plurality of marker holes  68  are used to place the fabric on locator pins when individual panels are sewn or welded together. These marker holes  68  are located in the seam allowance of the cover. 
       FIG. 5  depicts a second embodiment of a mattress and bed deck cover  130 . In this second embodiment, the means for removably fixing the cover  130  in relation to the mattress  10  and bed deck  20  is a long elastic band  144 , a short elastic band  146 , and a plurality of magnets  158 . The magnets  158  are enclosed within sealed pockets  156  formed by welding fabric to the inner surface  40  of the cover  130 . In this second embodiment, the means for removably fixing the cover  130  further includes a plurality of hooks  164 . As shown in  FIG. 5B , the hooks  160  may be attached to an elastic band  144 ,  146  or attached directly to the cover  130  by sewing fabric over the hooks  164 . 
     In this second embodiment, the cover  130  includes a plurality of cutouts, including first cutouts  160  and second cutouts  162 , in shapes and locations corresponding to devices attached to the bed deck  20 . As indicated by the first and second embodiments, the present invention may include any number or arrangement of cutouts  60 ,  160 ,  162  to fit different styles of beds  18  and provide access to devices extending therefrom. 
     In the second embodiment, the bed deck  20  is 36 (91 cm) inches wide by 80 inches (203 cm) long by 1.5 inches (3.8 cm) high. In this embodiment, the mattress  10  is sized 36.5 inches (93 cm) wide by 80 inches (203 cm) long by 6 inches (15 cm) high. In this embodiment, the mattress and bed deck cover  130  is sized to snugly fit the mattress  10  and bed deck  20 . The mattress and bed deck cover  130  is about 80 inches (203 cm) in long, 36.5 inches (93 cm) wide and 7.375 inches (18.7 cm) high. 
     In this second embodiment the head end channel  150  has a length of about 9.0 inches (22.9 cm), is located at a height of about 4.625 inches (11.75 cm) from the top surface  132  of the cover  130 , and has a height of 0.625 inches (1.6 cm). The foot end channel  152  has a length of about 15 inches (38.1 cm), is located at a height of about 4.75 inches (12.1 cm) from the top surface  132  of the cover  130 , and has a height of 0.375 inches (1.0 cm). The channels  150 ,  152  extend the full width of the cover  130 . Each side  138  of the cover includes two pockets  156  1.5 inches (3.8 cm) in height and 3 inches (7.6 cm) in length. The pockets  156  are located close to the bottom of the sides  138  and are respectively positioned about 12 inches (30.5 cm) and 15.25 inches (38.7 cm) from the head end  134 . Each pocket  156  encloses a magnet  158 . 
     The first cutouts  160  begin at the bottom edge of the sides  138 , adjacent to the head end  134  of the cover  130 , and increase in height at a angle of about 73 degrees to a height of about 5.25 inches (13.3 cm). The first cutouts  160  then extend for a length of about 1.7 inches (4.3 cm), for a total length of about 3.3 inches (8.4 cm). The second cutouts  162  begin at the bottom edge of the sides  138  of the cover  130  at a location 19 inches (48.3 cm) from the head end  134  with a height of 3.5 inches (8.9 cm). The second cutouts  162  extend for a length of 3 inches (7.6 cm), decrease to a height of 2 inches (5.1 cm), and extend for an additional 14 inches (35.6 cm), for a total length of 17 inches (43.2 cm). 
     In a preferred embodiment, the mattress and bed deck cover  30 ,  130  is capable of being laundered using healthcare laundering techniques. The cover  30 ,  130  is manufactured primarily using fabric welds. In present invention, 0.125 inch (0.318 cm) fabric welds are used with a pull strength of about 19.8 pounds per square inch (6.895 kPa), which are capable of withstanding the agitation and high temperature of the laundering process. In addition, the hemmed edges surrounding the long elastic band  44 ,  144  and short elastic band  46 ,  146  may incorporate a plurality of exit holes (not shown) approximately 0.125 inches (0.318 cm) in diameter. The exit holes permit trapped water to drain out during the laundering process. The hemmed edges surrounding the elastic bands  44 ,  144 ,  46 ,  146  are the only hemmed attachments on the cover; all others are welded. The magnets  58 ,  158  preferably include an epoxy coating to protect them from damage during the laundering process. 
     While the present invention is discussed primarily in context of a hospital setting, the mattress and bed deck cover  30 ,  130  may be used in non-hospital settings, or with non-adjustable beds. For example, the present invention may be used in nursing homes or hospice facilities. The present invention may also be used in the home, for example, for individuals with incontinence issues or with weeping sores, both of which would benefit from an antimicrobial sleeping surface which prevents contamination of underlying bedding. 
     The foregoing detailed description is given primarily for clearness of understanding and no unnecessary limitations are to be understood therefrom for modifications can be made by those skilled in the art upon reading this disclosure and may be made without departing from the spirit of the invention and scope of the appended claims.