Patent Publication Number: US-2011067182-A1

Title: Bed bug proof mattress

Description:
BACKGROUND OF THE INVENTION 
     The present invention generally relates to apparatus and methods for preventing bed bugs and mites from infiltrating mattresses. 
     Bed bugs are small insects that feed on human blood. They are usually active at night when people are sleeping. Adult bed bugs have flat, rusty-red-colored oval bodies. About the size of an apple seed, they are big enough to be easily seen, but often hide in cracks in furniture, floors, or walls. When bed bugs feed, their bodies swell and become brighter red. They can live for several months without food or water. When bed bugs infect an apartment dwelling they often reside in mattresses. When they reside in mattresses they typically reside not inside the mattress but rather under the seam of the mattress. 
     The following article about bed bugs in New York City was taken from a recent blog and illustrates the perniciousness of bed bugs. 
     “I&#39;m sorry we haven&#39;t hosted any play dates at our house,” a dad at school says the other day. “The truth is, we&#39;ve been fighting bed bugs for months.” His tale unfolds then—the kind of story that makes you wiggle and shiver and twitch just hearing it. Back in September, they take their daughter to their family doctor with what they expect are bed bug bites. The doctor says it&#39;s not bed bugs—he even says it a second time, at their next visit. By the time they finally prove him wrong, the bed bugs have a strangle-hold on their apartment. “I just wish we had found them right away,” he says. Finally after months of fighting back, they think it&#39;s over. Weeks later; more bites show up on their daughter. He carries the heavy look of someone fighting a long war.” 
     As of 2009, there is a full-blown bed bug outbreak across New York City and in other cities across the United States. The bed bugs are even in some of New York&#39;s fanciest hotels. According to the same article “The exterminator won&#39;t let his kids sit on the wood benches in the subway stations,” my friend says. “They house bed bugs, who can climb onto your clothes or into your bags.” People with the bed bug infestations talk about the social shame they have. “They look traumatized and weary”. 
     Bed bugs have not only infected residential dwellings, making life in many residential buildings intolerable, but have so seriously disturbed hotels that they have made life in such hotels so intolerable for patrons that they have hurt business. Hotels by definition have a lot of traffic and bed bug problems are exacerbated by traffic. 
     In contrast to other vermin, bed bugs are so insidious that courts have held that their presence in a residence constitutes constructive eviction. The protocol for exterminating bed bugs places such a toll on the residents of the apartments that this causes secondary damage. 
     Prior art solutions to bed bugs include exterminating the apartment with pesticides and sealing off mattresses with covers made of vinyl or other materials. Each cover has an opening to allow the cover to be placed on the mattress to enclose the mattress. Then the opening of the mattress, or in the case of covers with zippers, the zipper of the mattress, must be taped with duct tape. Variations on this procedure may exist. The problem is that the tape frequently falls off. In addition, in hotels, where linen is changed on a daily basis it is impractical to use this procedure. Even if this procedure were able to be used, the frequent linen changes would increases the chances that the tape would fall off. 
     As can be seen, there is a need for an effective and practical apparatus and method that solves the bed bug problem, particularly one that is easy to use. 
     SUMMARY OF THE PRESENT INVENTION 
     One aspect of the present invention is directed to a mattress, comprising an inner section; and a continuous uninterrupted outer layer comprised of (i) a bed bug retardant layer including a continuous polyester interlock fabric adjacent to a continuous plastic film, (ii) a fire retardant layer; (iii) a foam layer, the bed bug retardant layer quilted to the fire retardant layer and to the foam layer. 
     A further aspect of the present invention is directed to a mattress adapted to be free of bed bug infestation by means of a continuous outer layer made of a polyester interlock fabric laminated with a breathable polyurethane film so as to form a barrier preventing bed bugs from traversing or breeding in the outer layer. 
     In a still further aspect of the present invention, there is presented a method of preventing bed bugs from infesting beds of a hotel, comprising incorporating into mattresses of beds of the hotel a continuous uninterrupted outer layer comprised of (i) a bed bug retardant layer including a light weight interlock knit polyester laminated with a hydrophilic polyurethane film, (ii) a fire retardant layer; and (iii) a foam layer, the bed bug retardant layer quilted to the fire retardant layer and to the foam layer and containing a seam. 
     In a still further aspect of the present invention, there is presented a method of preventing bed bugs from infesting beds of a hotel, comprising incorporating a mattress into beds of the hotel, the mattress having an inner section and that has a continuous outer layer comprised of (i) a bed bug retardant layer including a light weight interlock with polyurethane film, (ii) a fire retardant layer; (iii) a foam layer, the bed bug retardant layer quilted to the fire retardant layer and to the foam layer and containing a seam. 
     In a further aspect of the present invention, the present invention is directed to a method of making a bed bug retardant mattress, comprising laminating a hydrophilic polyurethane film to a polyester interlock knit to form a bed bug retardant layer; quilting the bed bug retardant layer to a fire retardant layer and to a foam layer to form an outer layer; and joining the outer layer to an inner section to form a mattress. 
     These and other features, aspects and advantages of the present invention will become better understood with reference to the following drawings, descriptions and claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a mattress in accordance with one embodiment of the present invention; 
         FIG. 1A  is a perspective view of a mattress in accordance with one embodiment of the present invention including a sectional view of layers of one corner of the mattress; 
         FIG. 2  is a perspective view of the mattress of  FIG. 1  at a juncture of a top and side of the mattress showing the outer layer in section and showing a portion of the inside of the mattress; 
         FIG. 3  is a sectional view of the mattress of  FIG. 1A  taken along a line  3 - 3  of  FIG. 1A ; 
         FIG. 4  is a sectional view of the mattress of  FIG. 1A  taken along a line  4 - 4  of  FIG. 1A ; 
         FIG. 5  is sectional view of the mattress of  FIG. 1  at a juncture of a side and top surface and showing the seam; 
         FIG. 6  is a fragmentary perspective view of the mattress of  FIG. 1  at a corner thereof showing the outer layer in section and showing an inside portion of the corner of the mattress in phantom lines; 
         FIG. 7  is a sectional view of a portion of the length of the bed bug retardant layer showing its sublayers; and 
         FIG. 8  is a sectional view of the outer layer showing a portion of the bed bug retardant layer quilted to the fire retardant layer and the elastic layer. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The following detailed description is of the best currently contemplated modes of carrying out the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims. 
     The present invention generally provides a mattress that may be bed bug proof. The mattress incorporates a continuous outer layer enclosing the entire inner section of the mattress. The outer layer may include a bed bug retardant layer made of a light weight interlock polyester laminated with a hydrophilic polyurethane film of approximately one mil thick by adhering one side of the polyester layer to the polyurethane film. The bed bug retardant layer may be quilted to a fire retardant layer and to a foam layer. 
     In contrast to the prior art, in which a standard mattress has to be covered with a bed bug proof cover that of necessity has an opening for ingress and egress, the mattress of the present invention includes a continuous outer layer integrally joined to the mattress during the manufacturing of the mattress that may have no openings. In further contrast to the prior art, in which a mattress is first covered with a cover to prevent bed bug infestation, the mattress of the present invention may eliminate the need for any covering over it to seal against bed bugs. In further contrast to the prior art, in which tape is used to seal the mattress from bed bugs, the mattress of the present invention may not requires any tape, thus saving effort, time and cost. In further contrast to the prior art, in which tape is used to seal the mattress and the tape frequently falls off or is disturbed, especially on hotel bed mattresses where frequent linen changing increases the change of disturbing such tape, the mattress and method of the present invention may reliably allow hotels to overcome the bed bug problem and provide a mattress that prevents bed bugs while still permitting the routine of linen changes to proceed. The present invention would not require that the linen changes be more difficult because of the need to remove a special cover that was placed on the mattress specifically to protect against bed bugs. 
       FIG. 1  shows generally the mattress  10  of the present invention. Mattress  10  may comprise an inner section  99  that may be made of made of filler  98  and springs  97  (see  FIG. 6 ). Although the top surface of mattress  10  is quilted, as discussed further below, this is not intended to be apparent from  FIG. 1 . As seen in  FIG. 1A  the outer layer of mattress  10  has layers  22 ,  24 ,  26 . Again, the quilted nature of these layers is not intended to be apparent from  FIG. 1A . 
     As shown in  FIG. 3 , which shows the layers along a top panel of a mattress, mattress  10  may also include a continuous outer layer  20  comprised of a bed bug retardant layer  22 . As seen in  FIG. 7 , bed bug retardant layer  22  may itself be comprised of two sublayers, including a fabric layer  21  and a layer of film. Fabric sublayer  21  may be a light weight interlock knit fabric which may be polyester, and in one preferred embodiment 100% polyester. Interlocking knit refers to a very smooth knit that may allow few places for bed bugs or dust mites to accumulate. The sublayer of film  23  may be a hydrophilic moisture-curable polyurethane film. Polyurethane film  23  may be hydrophilic and may draw liquid perspiration from the body of a user lying on mattress  10 , thus providing comfort. Nonetheless, film sublayer  23  may not be porous and may even be without micropores so that film sublayer  23  may act as an effective barrier preventing bed bugs or dust mites from traversing sublayer  23  and into mattress. 
     Applicant has commissioned scientific tests on a sample mattress of the mattress  10  of the present invention. The sample mattress was subjected to actual live bed bugs. Nonetheless, the results of these scientific tests were that mattress  10  remained free of bed bugs. The tests supported, the conclusion that mattress  10  of the present invention prevents bed bugs from gathering or accumulating near or under seam  33 , where they usually do, or in other parts of mattress  10 . 
     In addition, bed bug resistant layer  22  may exhibit excellent wash resistance. 
     As shown in  FIG. 7 , the two sublayers of bed bug retardant layer  22  may be joined together to form bed bug retardant layer  22  by laminating interlocking knit fabric layer  21  on one side with film sublayer  23 . The process may include providing an adhesive  29 , which may be a discontinuous layer of adhesive  29 , between sublayers  21 ,  23 . For example, a dot formation of adhesive  29  may be used to provide a more aesthetic and more malleable and drapable overall layer  22 . Pressure and heat may be used in the lamination process. 
     The thickness of the bed bug retardant layer  22  may vary and may be approximately one mil. Alternatively, film sublayer  23  may be approximately one mil. A portion of the thickness of bed retardant layer  22  may be taken up by the adhesive coated hydrophilic polyurethane film  23 . In certain embodiments, the polyurethane film sublayer  23  may take up approximately 10 percent of the weight of the bed bug retardant layer  22 . For example, the overall weight of the bed bug retardant layer  22  may be approximately 3.75 ounces per square yard whereas the polyurethane film sublayer  23  including its adhesive coating may weigh approximately 0.3 ounces per square yard. 
     By being hydrophilic the polyurethane film may be breathable yet may simultaneously still act as a barrier preventing bed bugs from penetrating into the mattress. By being hydrophilic the mattress&#39; outer layer may be more comfortable since it absorbs the body&#39;s sweat without allowing moisture to penetrate the outer layer which could otherwise be a breeding ground four fungus, mold or bed bugs. 
     Continuous outer layer  20  of mattress  10  may also include a fire retardant layer  24  which may be bulbous in nature. Outer layer  20  may also include an elastic layer  26  that may typically be made of foam. 
     Bed bug retardant layer  22  may be attached to other layers of the mattress  10  in an integrated manner since bed bug retardant layer is an integral portion of mattress  10 . For example, as seen in  FIG. 8 , bed bug retardant layer  22  may be quilted to fire retardant layer  24  and to the foam layer  26  that is underneath fire retardant layer  24 . It is noted that other drawings figures herein besides  FIG. 8  do not depict the quilted nature of the layers  22 ,  24 ,  26  either because such figures showing sectional views may be deemed to depict the portion of these layers at points between the quilted points or, as in the case of  FIG. 1 ,  FIG. 1A ,  FIG. 2  and  FIG. 6 , the criss-cross pattern is not to reflect the quilting without showing the three-dimensional nature of the quilting. 
     As can be seen from  FIG. 1 ,  FIG. 2  and  FIG. 5 , bed bug retardant layer  22  may contain a seam  33  that runs along a perimeter of the top of mattress  10  as well as along a perimeter of the underside of mattress  10 . As a result of the fact that bed bug retardant layer  22  repels bed bugs, seam  33  may be free of bed bugs. Otherwise, bed bugs would hide under the crease between seam  33  and a top surface of the top layer of mattress  10 . Although seam  33  may be composed of the layers of outer layer  20 , seam  33  may be held in place by means of a polyester fastening means such as a thread. 
       FIG. 4 , a sectional view along a side panel of mattress  10 , shows the same bed bug retardant layer  22 , fire resistant layer  24  and elastic layer  26  above spring  97  that is shown in  FIG. 3 . Whereas  FIG. 4  is a sectional view taken along a side panel,  FIG. 3  is a sectional view taken along the top panel/surface of mattress  10 . it is noted that outer layer  20  may be a continuous uninterrupted outer layer that entirely envelopes and encases the more inward portions of mattress  10 . Standard mattress may however incorporate additional filler layers  98  below the top surface of the mattress as shown in  FIG. 3  but such filler layers  98  may not appear inward of the side panels of the mattress  10 . 
     The present invention may also be expressed as a method of preventing bed bugs from infesting beds of a hotel. This method may include a step of incorporating into mattress of beds of the hotel a continuous uninterrupted outer layer comprised of (i) a bed bug retardant layer including a light weight interlock knit polyester laminated with a hydrophilic polyurethane film, (ii) a fire retardant layer; (iii) a foam layer, the bed bug retardant layer quilted to the fire retardant layer and to the foam layer and containing a seam. The method may also include a further step, in certain embodiments, of changing linen on the beds without having to remove a special cover related to bed bugs. 
     The present invention may also be expressed as a method of making a bed bug retardant mattress, comprising laminating a polyester interlock knit with a polyurethane film to form a bed bug retardant layer; quilting the bed bug retardant layer to a fire retardant layer and to a foam layer; and joining an inner section to the quilted bed bug retardant layer form a mattress. 
     It should be understood, of course, that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims.