Patent Description:
This disclosure relates generally to mattress toppers and air tables for making mattress toppers. This disclosure further relates to methods of making mattress toppers with an air table.

Mattress toppers are often used to add cushion and/or support to mattresses. The mattress toppers often appear bulky and out of place. Furthermore, stress placed on the mattress topper during use (e.g., while sleeping on the mattress topper) can cause seams of the mattress topper to tear through the fabrics of the mattress topper, thus, shortening a lifetime of the mattress topper.

Making mattress toppers (e.g., performing sewing functions on a mattress topper) can be difficult because the mattress toppers are often heavy and difficult to maneuver while sewing. Sewing tables used to make mattress toppers often require multiple people to maneuver a mattress topper while sewing the mattress topper, and a weight of the mattress topper can often cause difficulty and/or mistakes while sewing the mattress topper.

The present invention provides a mattress topper and a method of making such a mattress topper as claimed in claims <NUM> and <NUM>. Preferred features are set out in claims <NUM>-<NUM> and <NUM>-<NUM>.

For a detailed understanding of the present disclosure, reference should be made to the following detailed description, taken in conjunction with the accompanying drawings, in which like elements have generally been designated with like numerals, and wherein:.

The illustrations presented herein are not actual views of any mattress topper, air table, or any component thereof, but are merely idealized representations, which are employed to describe the present invention.

As used herein, any relational term, such as "first," "second," "adjacent," "top," "bottom," "lower," "upper," "middle," "beneath," "above," "below," etc., is used for clarity and convenience in understanding the disclosure and accompanying drawings, and does not connote or depend on any specific preference or order, except where the context clearly indicates otherwise. For example, these terms may refer to an orientation of elements of a mattress topper when disposed on a mattress in a conventional manner. Furthermore, these terms may refer to an orientation of elements of an air table when assembled on a ground surface.

As used herein, the term "substantially" in reference to a given parameter, property, or condition means and includes to a degree that one skilled in the art would understand that the given parameter, property, or condition is met with a small degree of variance, such as within acceptable manufacturing tolerances. For example, a parameter that is substantially met may be at least about <NUM>% met, at least about <NUM>% met, or even at least about <NUM>% met.

The present invention provides a mattress topper for fitting to a mattress and adding cushion and/or support to the mattress. The mattress topper includes a lower layer, an upper layer, and a side layer. The lower and side layers may include woven fabrics and the upper layer may include a knitted fabric. The lower and upper layers are at least generally a size of a top of a mattress upon which the mattress topper is to be fitted. Furthermore, the lower and upper layers may rest on the top of the mattress when the mattress topper is fitted to a mattress. The side layer may include at least one strip of material and may be shaped similar to a bed skirt or fitted sheet. In other words, the side layer is sized and shaped to extend down along a side of the mattress from the lower layer and the upper layer. The lower layer, upper layer, and side layer are connected together with a seam. The seam is sewn along a peripheral edge of the lower and upper layers. The seam includes a plurality of threads, and the threads of the seam are borne by the side layer and the lower layer. The side layer and the lower layer may serve to protect the upper layer of the mattress topper. The side layer is sized and shaped to extend from the seam and then fold back on itself to extend down along the side of the mattress.

According to the invention, the mattress topper having a deformable support layer disposed between the lower layer and the upper layer. The deformable layer may include a gel material.

The present invention also provides a method of making a mattress topper with an air table.

The air table is configured to provide lift to the mattress topper while the mattress topper is being sewn. According to invention, the air table is configured to lift up the mattress topper with air. The air table includes a top structure that includes a top panel having a plurality of vents extending therethrough. The air table may also include an air supply to blow air through the vents. Accordingly, the mattress topper is placed above the plurality of vents of the top panel of the top structure of the air table, and air is caused to blow through the plurality of vents to provide lift to the mattress topper. In other words, the mattress topper may is caused to "float" (e.g., hover) above a top surface of the top panel due to the air being blown through the plurality of vents.

<FIG> is a partial cross-sectional view of a mattress topper <NUM> not according to an embodiment of the present disclosure. Some features of the mattress topper <NUM> of <FIG> may be exaggerated and/simplified to better show features of the mattress topper <NUM> and for clarity. The mattress topper <NUM> may be disposable on (e.g., fitted to) a mattress to add cushion (e.g., softness, comfort, pressure relief, etc.) and/or support (e.g., body support, spinal alignment, etc.) to the mattress. The mattress topper <NUM> includes a lower layer <NUM>, an upper layer <NUM>, and a side layer <NUM>. The lower layer <NUM>, the upper layer <NUM>, and the side layer <NUM> are connected together (e.g., sewn together) with a seam <NUM>. The seam <NUM> includes a plurality of threads <NUM>, and the seam <NUM> may extend along and proximate to a peripheral edge of the mattress topper <NUM>. At the seam <NUM>, the side layer <NUM> is oriented adjacent to the upper layer <NUM>, which in turn, is oriented adjacent to the lower layer <NUM>. In other words, the upper layer <NUM> is disposed between the side layer <NUM> and the lower layer <NUM> at the seam <NUM> of the mattress topper <NUM>.

The lower layer <NUM> and the upper layer <NUM> of the mattress topper <NUM> may be generally the same size as a top of a mattress upon which the mattress topper <NUM> is to be fitted. For example, the lower layer <NUM> and the upper layer <NUM> may be generally the same size as a top of a twin, full, queen, king, or California king mattress depending on the size of the mattress. The side layer <NUM> may be sized and shaped similar to a bed skirt or fitted sheet. The side layer <NUM> includes a strip of material sewn with the seam <NUM> to the outer peripheral edge of the upper and lower layers <NUM>, <NUM>. In other words, the side layer <NUM> is sized and shaped to extend down from the upper layer <NUM> and the lower layer <NUM> along a side of the mattress and to at least substantially fully expose the upper layer <NUM>. In some embodiments, the side layer <NUM> may be sized and shaped to extend along a full height of the mattress and to be at least partially tucked under the mattress. In some embodiments, the side layer <NUM> may include an elastic member <NUM> attached to the side layer <NUM> along an inner edge of the side layer <NUM> (e.g., an edge opposite the seam <NUM> and an edge that would be tucked under a mattress during use). The elastic member <NUM> may help keep the mattress topper <NUM> fitted to the mattress. Alternatively, other means may be employed for this same purpose, such as a partially sewn-in cord that can be tightened (cinched) and/or tied.

In some embodiments, the upper layer <NUM> may include a knitted fabric that is relatively more prone to unraveling and to tearing and less robust relative to the side layer <NUM> and the lower layer <NUM>, which may include woven fabrics. Disposing the upper layer <NUM> (i.e., the more delicate fabric) between the side layer <NUM> and the lower layer <NUM> (i.e., the more robust fabrics) at the seam <NUM> and seaming the side layer <NUM>, the upper layer <NUM>, and the lower layer <NUM> together with the seam <NUM> in such an orientation may provide a more robust seam <NUM> and connection between the layers <NUM>, <NUM>, <NUM> The lower layer <NUM> and the side layer <NUM> bear the threads <NUM> of the seam <NUM>. In other words, threads <NUM> of the seam <NUM> bear against the fabrics of the lower layer <NUM> and the side layer <NUM>, and the threads <NUM> of the seam <NUM> simply pass through the fabric of the upper layer <NUM>. Furthermore, due to the fabric of the side layer <NUM> and the lower layer <NUM> being woven, the side and lower layers <NUM>, <NUM> may be less likely to let the seam <NUM> tear through the side layer <NUM> and the lower layer <NUM>. Furthermore, having the side and lower layers <NUM>, <NUM> bear the threads <NUM> of the seam <NUM> may reduce stress placed on the upper layer <NUM> by the seam <NUM> during use of (i.e., while sleeping on) the mattress topper <NUM>. Accordingly, the side layer <NUM> and the lower layer <NUM> may serve to protect the more delicate upper layer <NUM>, and a lifetime of the mattress topper <NUM> may be extended. Furthermore, the seam <NUM> may be more robust (e.g., durable, strong, effective, etc.) than if the threads <NUM> of the seam <NUM> were to bear against the upper layer <NUM>. Also, during sewing procedures, sewing the seam <NUM> in the orientation described above, avoids any need to close the seam <NUM> prior to trimming (e.g., cutting) the upper layer <NUM> (i.e., knitted layer).

As discussed above, the mattress topper <NUM> may be fitted to a mattress, and the side layer <NUM> of the mattress topper <NUM> is folded back on the seam <NUM> and oriented to extend along the sides of a mattress. The side layer <NUM> may serve to secure the mattress topper <NUM> to the mattress and to at least partially hold the mattress topper <NUM> in place relative to the mattress.

<FIG> shows a partial cross-sectional view of a mattress topper <NUM> according to another embodiment of the present invention.

Some features of the mattress topper <NUM> of <FIG> may be exaggerated and/or simplified to better show features of the mattress topper <NUM> and for clarity. The mattress topper <NUM> is similar to the mattress topper <NUM> of the <FIG> and includes a deformable support layer <NUM> disposed between the upper layer <NUM> and the lower layer <NUM> of the mattress topper <NUM>.

In some embodiments, the deformable support layer <NUM> material may include a hyper-elastic polymer. For example, the deformable support layer <NUM> may be formed entirely from a gel, or the deformable support layer <NUM> may have a composition comprising a gel and one or more additional non-gel materials. Such gels and gel compositions are described in, for example, <CIT>, <CIT>, and <CIT>. In one embodiment, the gel may include an elastomeric gel comprising between about <NUM> to about <NUM> parts plasticizer per <NUM> parts solid elastomer by weight. For example, in one embodiment, the gel may comprise KRATON® E1830 elastomer and a white food grade mineral oil, such as CARNATION® oil. In another embodiment, the gel may comprise SEPTON® <NUM> elastomer and a white food grade mineral oil. In additional embodiments, the gel may comprise a polyurethane-based gel, a silicone-based gel, and a PVC-based gel. The deformable support layer <NUM> may be a bare un-coated deformable support layer <NUM>, or the deformable support layer <NUM> may be coated, covered with, adhered to, fused with, or integral with another material. For example, the deformable support layer <NUM> may include a cushion layer similar to the cushion described in <CIT>.

The deformable support layer <NUM> may have a thickness within the range of about <NUM> inch (<NUM>) to about <NUM> inches (<NUM>). In some embodiments, the deformable support layer <NUM> may have a thickness of about <NUM> inches (<NUM>).

In some embodiments, the lower layer <NUM> of the mattress topper <NUM> may comprise a scrim fabric (e.g., a woven or non-woven fabric material) and portions of the deformable support layer <NUM> may seep through (e.g., be melt-fused into, bleed through, push through, leak through, pass through, etc.) the scrim fabric of the lower layer <NUM>. For example, when the deformable support layer <NUM> includes a gel material, portions of the gel material may be heat fused through the lower layer <NUM> of the mattress topper <NUM>. The portions of the deformable support layer <NUM> that extend through the scrim fabric of the lower layer <NUM> may create a non-slip surface or reduced slip surface on a lower surface <NUM> of the lower layer <NUM> (e.g., surface that would contact a mattress) of the mattress topper <NUM>. The non-slip surface or reduced slip surface created by the deformable support layer <NUM> may help the mattress topper <NUM> stay in place relative to a mattress when fitted to a mattress.

In addition to the deformable support layer <NUM>, the mattress topper <NUM> may include one or more deformable layers of foam, felt, gel, air chambers, or other fibers (as a non-limiting example, polyester batting fill material).

The seam <NUM> of the mattress topper <NUM> may be separated from the deformable support layer <NUM> by a distance D along a plane defined by a bottom surface <NUM> of the deformable support layer <NUM> and in a direction perpendicular to a side of the deformable support layer <NUM> facing the seam <NUM>. In some embodiments, distance D may be within a range of about <NUM> inch (<NUM>) to about <NUM> inches (<NUM>), a range of about <NUM> inch (<NUM>) to about <NUM> inches (<NUM>), or a range of about <NUM> inch (<NUM>) to about <NUM> inches (<NUM>). For example, distance D may be about <NUM> inch (<NUM>). The deformable support layer <NUM> may have a general rectangle shape (e.g., the general shape of a mattress), and the seam <NUM> may be separated from each end (i.e., both longitudinal ends and lateral ends) of the deformable support layer <NUM> by distance D.

<FIG> shows a partial cross-sectional view of the mattress topper <NUM> of <FIG> fitted on a mattress <NUM> and shows a drop down feature of the mattress topper <NUM>. Some features of the mattress topper <NUM> and the mattress <NUM> of <FIG> may be exaggerated and/or simplified to better show features of the mattress topper <NUM> and the mattress <NUM> and for clarity. Referring to <FIG> and <FIG> together, because the seam <NUM> of the mattress topper <NUM> is separated from the deformable support layer <NUM> by distance D, the seam <NUM> may drop below a bottom surface <NUM> of the deformable support layer <NUM> when the mattress topper <NUM> is fitted to the mattress <NUM>. In other words, the fabric of the upper layer <NUM> and the fabric of the lower layer <NUM> may extend past a top <NUM> of the mattress <NUM> and may extend at least some distance down a side of the mattress <NUM>. To facilitate description of the mattress topper <NUM> in the present disclosure, the upper and lower layers <NUM>, <NUM> extending down at least some distance along a side of the mattress <NUM> will be referred to hereinafter as the "drop down feature.

The drop down feature of the mattress topper <NUM> may help prevent a seam of the mattress <NUM> and the seam <NUM> of the mattress topper <NUM> from being immediately adjacent to (e.g., stacked on top of) each other. By not stacking the seams, the mattress topper <NUM> may avoid a bulging appearance when fitted to a mattress <NUM>. As a result, the drop down feature of the mattress topper <NUM> may provide the mattress topper <NUM> with a blended transition appearance when fitted to the mattress <NUM>. Furthermore, the drop down feature may provide a more aesthetically pleasing appearance when fitted to a mattress <NUM>. Moreover, by distancing the seam <NUM> of the mattress topper <NUM> from a seam of the mattress <NUM> (e.g., keeping the seam <NUM> of the mattress topper <NUM> from stacking onto the seam of the mattress <NUM>), less stress may be placed on the seam <NUM> when fitting the mattress topper <NUM> to the mattress <NUM> and during use of (e.g., when sleeping on) the mattress topper <NUM>. Reducing stress on the seam <NUM> of the mattress topper <NUM> may extend a life of the mattress topper <NUM>.

<FIG> is a perspective view of an air table <NUM> that may be used when making (e.g., sewing) the mattress toppers <NUM> of <FIG> according to an embodiment of the present invention. Referring to <FIG> and <FIG> together, the air table <NUM> is used to at least partially lift up a mattress topper <NUM> with air (i.e., provide lift to the mattress topper <NUM>) to facilitate making the mattress topper <NUM>. Mattress toppers <NUM> having the deformable support layer <NUM> can be relatively heavy, and because the deformable support layer <NUM> may extend through the lower layer <NUM> of the mattress topper <NUM>, the mattress toppers <NUM> may be difficult to maneuver especially when such extension of material is meant t create a non-slip or non-skid effect. Thus, lifting the mattress toppers <NUM> with air (e.g., causing the mattress topper <NUM> to at least partially float or hover above the air table <NUM>) can help facilitate fabrication of the mattress toppers <NUM> and, in particular, the sewing of the seam <NUM>.

The air table <NUM> includes a top structure <NUM>, a plurality of legs <NUM>, at least one air supply <NUM>, and a plurality of vents <NUM>. The top structure <NUM> includes a top panel <NUM> and a bottom panel <NUM>. The plurality of vents <NUM> extend through the top panel <NUM> of the top structure <NUM>. The plurality of legs <NUM> may extend from the bottom panel <NUM> of the top structure <NUM> and, when the air table <NUM> is in use and assembled, may rest on a ground surface. In some embodiments, the at least one air supply <NUM> may be disposed beneath the top structure <NUM> of the air table <NUM> and may be attachable to the bottom panel <NUM> of the top structure <NUM>. In other embodiments, the at least one air supply <NUM> may be attachable to a sidewall or the top panel <NUM> of the air table <NUM>. Regardless, the at least one air supply <NUM> may be oriented to blow air into the top structure <NUM> of the air table <NUM>. In some embodiments, the at least one air supply <NUM> may include a centrifugal blower.

In some embodiments, the plurality of vents <NUM> may be formed (e.g., oriented) in the top panel <NUM> of the top structure <NUM> in a pattern. In other words, the plurality of vents <NUM> may be oriented in a pattern with respect to one another. For example, in some embodiments, the plurality of vents <NUM> may be oriented in a one-inch grid pattern. In other words, the plurality of vents <NUM> may be spaced apart from one another by about <NUM> inch (<NUM>) along a length of the air table <NUM> and along a width of the air table <NUM>. In other embodiments, the plurality of vents <NUM> may be oriented in a grid pattern and may be spaced apart from each other by about <NUM> inch (<NUM>) to about <NUM> inches (<NUM>). In other embodiments, the plurality of vents <NUM> may be oriented in circles, concentric rectangles, or any other pattern.

In some embodiments, the air table <NUM> may have a longitudinal length within a range of about <NUM> inches (<NUM>) to about <NUM> inches (<NUM>). For example, the air table <NUM> may have a longitudinal length of about <NUM> inches (<NUM>). In some embodiments, the air table <NUM> may have a lateral width within a range of about <NUM> inches (<NUM>) to about <NUM> inches (<NUM>). For example, the air table <NUM> may have a lateral width of about <NUM> inches (<NUM>). As a non-limiting example, the air table <NUM> may accommodate articles at least a size of a California King size mattress topper. However, although specific dimensions are provided in the present disclosure, one of ordinary skill in the art would readily recognize that a size of the air table <NUM> could be adjusted to accommodate different sizes of articles that may be made with the air table <NUM>.

The top surface of the top panel <NUM> of the top structure <NUM> may be located between about <NUM> inches (<NUM>) and about <NUM> inches (<NUM>) from a ground surface when the air table <NUM> is assembled. A top surface (e.g., working surface) at this height may provide a comfortable working surface for seated operators of the air table <NUM>. In other words, the height of the top surface may reduce fatigue a user may experience when using the air table <NUM>.

When the air table <NUM> is operating, the at least one air supply <NUM> may blow air into the top structure <NUM> of the air table <NUM> and the air may escape (e.g., be blown) through the plurality of vents <NUM>. The air blown out of the plurality of vents <NUM> provides a lift for lifting articles placed on the air table <NUM>, the lift provided by a thin sheet of flowing air between the article placed on the air table <NUM> and the top surface of the air table <NUM>.

In some embodiments, the air table <NUM> may be mountable to a ground surface with fasteners coupled with the plurality of legs <NUM> of the air table <NUM>. Mounting the air table <NUM> to a ground surface may provide additional stability and predictability when operating the air table <NUM>.

<FIG> is a partial cross-sectional side view of the top structure <NUM> of the air table <NUM> of <FIG>. The top structure <NUM> includes the top panel <NUM>, the bottom panel <NUM>, an air chamber <NUM>, the plurality of vents <NUM>, at least one air intake hole <NUM>, a sidewall <NUM>, and at least one support member <NUM>. The top panel <NUM> may be oriented above the bottom panel <NUM> and may at least partially define the air chamber <NUM> between the top panel <NUM> and the bottom panel <NUM>. The sidewall <NUM> may extend along outer peripheral edges of the top panel <NUM> and bottom panel <NUM> and may extend between the top panel <NUM> and the bottom panel <NUM>. The sidewall <NUM> may also at least partially define the air chamber <NUM>.

The plurality of vents <NUM> extend through the top panel <NUM> of the top structure <NUM>. For example, the plurality of vents <NUM> may extend from a bottom surface <NUM> of the top panel <NUM> to the top surface <NUM> of the top panel <NUM>. Each vent <NUM> of the plurality of vents <NUM> may include a large section <NUM> and a small section <NUM>. The large section <NUM> of a respective vent <NUM> may have a larger diameter than a diameter of the small section <NUM> of the respective vent <NUM>. The large section <NUM> may extend from the bottom surface <NUM> of the top panel <NUM> (i.e., surface facing the air chamber <NUM>) and may extend partially through the top panel <NUM> but may not extend completely through the top panel <NUM>. For example, the large section <NUM> of a respective vent <NUM> may extend halfway or over halfway through the top panel <NUM>. The small section <NUM> may extend from the large section <NUM> of the vent <NUM> and may extend through a remainder of the top panel <NUM> and through a top surface <NUM> of the top panel <NUM>.

The large sections <NUM> of the plurality of vents <NUM> may have diameters within a range of about <NUM> inch (<NUM>) to about <NUM> inches (<NUM>). For example, in some embodiments, the large sections <NUM> may have diameters of about <NUM> inch (<NUM>). The small sections <NUM> of the plurality of vents <NUM> may have diameters within a range of about <NUM> inch (<NUM>) to about <NUM> inch (<NUM>). For example, in some embodiments, the small sections <NUM> may have diameters of about <NUM> inch (<NUM>).

The large sections <NUM> of the plurality of vents <NUM> may have longitudinal lengths within a range of about <NUM> inch (<NUM>) to about <NUM> inches (<NUM>). For example, the large sections <NUM> of the plurality of vents <NUM> may have longitudinal lengths of about <NUM> inch (<NUM>). The small sections <NUM> of the plurality of vents <NUM> may have longitudinal lengths within a range of about <NUM> inch (<NUM>) to about <NUM> inches (<NUM>).

The large sections <NUM> and the small sections <NUM> of the plurality of vents <NUM> may enable a velocity (e.g., speed) of the air traveling through the plurality of vents <NUM> to be increased. For example, the air traveling through the plurality of vents <NUM> may experience a Venturi effect, which is known in the art, where a velocity of a fluid flows through a constricted section (i.e., small sections <NUM> of the plurality of vents <NUM>) of a pathway increase. Increasing a velocity of the air traveling through the plurality of vents <NUM> may provide increased lift near the top surface <NUM> of the top panel <NUM> of the air table <NUM>. For example, when wanting to provide lift to an object, increasing air velocity is often more effective than increasing a pressure of the air. Thus, by increasing a velocity of the air traveling through the plurality of vents <NUM> of the air table <NUM>, the lift provided by the air (i.e., force placed against an object disposed on the top surface <NUM> of the top panel <NUM> of the air table <NUM> by the air) is increased. In some embodiments, the diameters of the large sections <NUM> and the small sections <NUM> may be selected to provide a certain amount of lift (e.g., force) for a selected amount of air flow.

Having the small sections <NUM> of the plurality of vents <NUM> extend through only a portion of the top panel <NUM> (e.g., reducing a length of the small sections <NUM>) instead of the completely through the top panel <NUM> (i.e., by including the large sections <NUM>), may reduce a resistance that air experiences when traveling through the plurality of vents <NUM>. As a result, a flow rate of the air may be less affected by the resistance, which reduces a load on the at least one air supply <NUM> to maintain a selected flow rate, which saves on costs and makes the air table <NUM> more efficient.

The longitudinal axis <NUM> of each vent <NUM> of the plurality of vents <NUM> is orthogonal to the top surface <NUM> of the top panel <NUM> of the top structure <NUM>.

The top and bottom panels <NUM>, <NUM> may have thicknesses within a range of about <NUM> inch (<NUM>) to about <NUM> inches (<NUM>). For example, the top and bottom panels <NUM>, <NUM> may thicknesses of about <NUM> inch (<NUM>). In some embodiments, the top and bottom panels <NUM>, <NUM> may include one or more of a medium-density fiberboard ("MDF") material, particle board, plywood, wood, or a polymer material.

In some embodiments, the at least one air intake hole <NUM> may extend through the bottom panel <NUM> of the top structure <NUM> of the air table <NUM>. In other embodiments, the at least one air intake hole <NUM> may extend through a sidewall <NUM> or the top panel <NUM> of the air table <NUM>. In some embodiments, the at least one air intake hole <NUM> may be generally centered between lateral and longitudinal sides of the air table <NUM>. In some embodiments, the air table <NUM> may include two or more air intake holes <NUM>, and the two or more air intake holes <NUM> may be generally evenly spaced apart to give at least generally consistent airflow throughout the air chamber <NUM> of the air table <NUM>. The at least one air supply <NUM> may be aligned with (e.g., connected to the air table <NUM> at) the at least one air intake hole <NUM> and may provide air to the air chamber <NUM> of the air table <NUM> through the at least one air intake hole <NUM>.

The at least one support member <NUM>, if any, may be disposed in the air chamber <NUM> of the air table <NUM>, may extend between the top panel <NUM> and the bottom panel <NUM>, and may support the top panel <NUM>. In some embodiments, the at least one support member <NUM> may include at least one post made of a structural material such as, for example, metal, wood, or plastic. In some embodiments, the at least one support member <NUM> may include two or more support members <NUM>, and the two or more support members <NUM> may be at least substantially evenly distributed (e.g., spaced apart from one another) within the air chamber <NUM> of the air table <NUM> and between the top panel <NUM> and the bottom panel <NUM>. However, the air table <NUM> may not include too many support members <NUM>. In other words, the air table <NUM> may not include a number of support members <NUM> that would detrimentally reduce airflow to the plurality of vents <NUM> of any portion of the air table <NUM>.

<FIG> is a partial cross-sectional side view of the air table <NUM> of <FIG> having the mattress topper <NUM> of <FIG> disposed thereon. Some elements of <FIG> may be exaggerated and/or simplified to better show elements of the air table <NUM> and the mattress topper <NUM> and for clarity. As discussed above, the air table <NUM> provides lift under the mattress topper <NUM> to help an operator maneuver the mattress topper <NUM> while sewing the mattress topper <NUM> (e.g., sewing the seam <NUM>).

In some embodiments, the mattress topper <NUM> may be at least substantially permeable and would likely not be lifted by the air table <NUM> if placed in direct contact with the air table <NUM>. Thus, to provide lift to the mattress topper <NUM>, a substrate panel <NUM> may be placed between the mattress topper <NUM> and the air table <NUM>. The substrate panel <NUM> may be at least substantially "airtight" (e.g., may not let a significant amount of air pass therethrough). For example, the substrate panel <NUM> may include a panel of a polymer material, cardboard, STYROFOAM®, metal, fabric, or any other airtight or low-air permeable material.

During use, air blown through the plurality of vents <NUM> of the air table <NUM> pushes the substrate panel <NUM> and may exert a force on the substrate panel <NUM>. The force exerted on the substrate panel <NUM> causes the substrate panel <NUM> to lift up (e.g., hover, float, etc.) relative to the top surface <NUM> of the top panel <NUM> of the air table <NUM> such that at least some air is between the substrate panel <NUM> and the top surface <NUM> of the top panel <NUM> of the air table <NUM>. By lifting the substrate panel <NUM>, the air table <NUM> may also lift a mattress topper <NUM> that is placed on the substrate panel <NUM>.

In some embodiments, the substrate panel <NUM> may be smaller in size than a mattress topper <NUM> when viewed from a plane defined by the top surface <NUM> of the air table <NUM> (e.g., a plane that is perpendicular to the plane defined by <FIG>). In other words, the substrate panel <NUM> may not extend past or to the peripheral edge of the mattress topper <NUM> when the mattress topper <NUM> is disposed on the substrate panel <NUM>. The smaller size of the substrate panel <NUM> may allow portions of the mattress topper <NUM> to brush against (e.g., touch) the air table <NUM> when the substrate panel <NUM> and mattress topper <NUM> are lifted by the air table <NUM>. In other words, portions of the mattress topper <NUM> may hang over an outer peripheral edge of the substrate panel <NUM> and may drop onto the air table <NUM>. Having portions of the mattress topper <NUM> touch the air table <NUM> may help to reduce and/or prevent unintentional movement of the mattress topper <NUM>. For example, having portions of the mattress topper <NUM> touch the air table <NUM> may prevent the mattress topper <NUM> from moving unintentionally while being lifted by the air table <NUM>.

Reducing and/or preventing unintentional movement of the mattress topper <NUM> may provide greater control of the mattress topper <NUM> when maneuvering the mattress topper <NUM> on the air table <NUM>. Greater control of the mattress topper <NUM> when maneuvering the mattress topper <NUM> may lead to fewer mistakes while making the mattress topper <NUM> and may increase safety for an operator when sewing the mattress topper <NUM>.

Moreover, the smaller size of the substrate panel <NUM> may help to keep at least some distance between the substrate panel <NUM> and the seam <NUM> of the mattress topper <NUM>. The distance between the substrate panel <NUM> and the seam <NUM> of the mattress topper <NUM> may keep the substrate panel <NUM> from interfering with the seam <NUM> of the mattress topper <NUM> when an operator is sewing the seam <NUM>. For example, while the mattress topper <NUM> is lifted by the air table <NUM>, an operator may sew the seam <NUM> of the mattress topper <NUM>.

In some embodiments, multiple substrate panels <NUM> may be used instead of a single substrate panel <NUM>. For example, when sewing a relatively large article, such as a king sized mattress topper <NUM>, multiple substrate panels <NUM> may be used to lift different portions of the king sized mattress topper <NUM>.

Referring to <FIG> and <FIG> together, depending on the size of an article being sewn, an amount of lift (e.g., a force being applied to the substrate panel <NUM> by the air being blown through the plurality of vents <NUM>) may be adjusted by adjusting how much air is being blown into the air chamber <NUM> of the air table <NUM> by the at least one air supply <NUM>. For example, when sewing a relatively heavy article, such as a mattress topper <NUM> comprising a gel layer, an amount of lift may be increased, and when sewing a relatively light article, such as a mattress topper <NUM> comprising a foam layer (and not a gel layer), an amount of lift may be decreased.

<FIG> is a top view of an air table <NUM> having a top panel <NUM> removed to better show internal elements of the air table <NUM>. In some embodiments, the air table <NUM> may include one or more divider members <NUM>. The divider members <NUM> may be disposed within the air chamber <NUM> (<FIG>) of the air table <NUM> and may divide the air chamber <NUM> into two or more air chamber portions 414a, 414b, 414c, etc. For example, the divider members <NUM> may divide the air chamber <NUM> into a first air chamber 414a portion and a second air chamber 414b portion. In such embodiments, each air chamber portion 414a, 416b may include a respected air intake hole <NUM> and an air supply <NUM>.

By dividing the air chamber <NUM> into two or more air chamber portions 414a, 414b, 414c, an operator may select which portions of the air table <NUM> the operator wishes to activate (e.g., turn on) when making an article. By being able to select which portions of an air table <NUM> the user wants to use, it may allow the user to use only portions of the air table <NUM> necessary for making the article. As a result, less energy (e.g., electricity) may be required when making smaller articles, which may lead to cost savings and increased efficiencies.

Furthermore, by dividing the air chamber <NUM> into two or more air chamber portions 414a, 414b, 414c, an operator may customize amounts of lift provided at different portions of the air table <NUM>. For example, some portions of the air table <NUM> may be set to provide more lift than other portions of the air table <NUM>.

<FIG> is a perspective view of an air table <NUM> according to another embodiment of the present disclosure. In some embodiments, the air table <NUM> may include a cutout portion <NUM> extending from a side of the air table <NUM> and toward a center of the air table <NUM>. <FIG> is a partial perspective view of the air table <NUM> of <FIG> and an insertable portion <NUM> having a sewing machine <NUM> attached thereto. Referring to <FIG> and <FIG> together, the insertable portion <NUM> may be sized and shaped to fit within the cutout portion <NUM> of the air table <NUM>.

The cutout portion <NUM> of the air table <NUM> may enable a sewing machine <NUM> to be disposed within a boundary defined by an outer peripheral edge of the air table <NUM>. Having the sewing machine <NUM> disposed within the boundary of the air table <NUM>, may allow the sewing machine <NUM> to perform sewing procedures on an article (e.g., sewing the seam <NUM> on a mattress topper <NUM>) without having the article extend beyond the boundary of the air table <NUM> (i.e., not being supported and/or lifted by the air table <NUM>).

Moreover, the cutout portion <NUM> may allow sewing machines <NUM> and respective insertable portions <NUM> used in conjunction with the air table <NUM> to be readily and quickly exchanged. As a result, sewing machines <NUM> for performing different sewing procedures (e.g., different sewing stitches) may be readily exchanged at a given air table <NUM> so that different sewing procedures can be performed on an article without moving that article from air table <NUM> to air table <NUM>.

<FIG> shows a flowchart of a process <NUM> of sewing an article on an air table <NUM>. Referring to <FIG> and <FIG> together, the process may include disposing an at least substantially airtight or a low-air-permeable substrate panel <NUM> on an air table <NUM>, as represented in act <NUM>. The substrate panel <NUM> may include one or more of a polymer material, cardboard, STYROFOAM®, metal, fabric, or any other airtight or low-air-permeable material. An article to be sewn may be disposed upon the substrate panel <NUM> such that the substrate panel <NUM> is disposed between the article and the substrate panel <NUM>, as represented in act <NUM>. In some embodiments, the article may include a mattress topper <NUM> such as the mattress toppers <NUM> described in regard to <FIG>.

An operator may cause the air table <NUM> to blow (e.g., expel) air through a plurality of vents <NUM> extending through a top surface <NUM> of air table <NUM> underneath the substrate panel <NUM>, as represented in act <NUM>. The air blown through the plurality of vents <NUM> may exert a force on the substrate panel <NUM> and/or article to be sewn. The substrate panel <NUM> and/or article may be caused to be lifted relative to (e.g., to float above) the air table <NUM> by the air blowing through the plurality of vents <NUM>, as represented in act <NUM>. An operator may maneuver the article relative to the air table <NUM> while the article is lifted relative to the air table <NUM>, as represented in act <NUM>. An operator may perform sewing procedures on the article while the article is lifted relative to the air table <NUM>, as represented in act <NUM>. In some embodiments, the sewing procedures may include sewing a seam <NUM> along a peripheral edge of the article (e.g., mattress topper <NUM>), as represented in act <NUM>.

Claim 1:
A mattress topper (<NUM>) for fitting to a mattress (<NUM>), comprising:
a lower layer (<NUM>) including a lower layer (<NUM>) peripheral portion;
a side layer (<NUM>) including an upper portion and a lower edge, the side layer (<NUM>) configured to be positioned adjacent to side edges of the mattress (<NUM>) and to extend down along the side edges of the mattress (<NUM>);
an upper layer (<NUM>) overlaying the lower layer (<NUM>) and including an upper layer (<NUM>) peripheral portion; and
a seam (<NUM>) comprising threads (<NUM>) and extending along peripheral edges of the lower layer (<NUM>) and the upper layer (<NUM>) and extending through the lower layer (<NUM>), upper layer (<NUM>), and side layer (<NUM>), the upper layer (<NUM>) peripheral portion being disposed between the lower layer (<NUM>) peripheral portion and the upper portion of the side layer (<NUM>) and the threads (<NUM>) secure the lower layer (<NUM>) peripheral portion, the upper layer (<NUM>) peripheral portion, and the upper portion of the side layer (<NUM>), with outer portions of the threads (<NUM>) of the seam (<NUM>) bearing against fabric of the lower layer (<NUM>) peripheral portion and fabric of the upper portion of the side layer (<NUM>), the threads (<NUM>) of the seam (<NUM>) simply passing through the upper layer (<NUM>), and the side layer (<NUM>) being folded back on the seam (<NUM>); and
a deformable support layer (<NUM>) disposed between the upper layer (<NUM>) and the lower layer (<NUM>).