Compressible encasement tray for bedding and method for selectively modifying bedding product with such a tray

Abstract

A bedding product for use as a mattress topper has a tray formed by a bottom sheet of compressible material with a generally rectangular frame attached at the periphery of a surface thereof, formed by rails of compressible material. The tray has a generally rectangular recess therein formed by the rails, which can be filled with inserts of selected firmness characteristics, to give the overall bedding product selected characteristics related to firmness.

We claim as our invention:  
     
         1 . A bedding product comprising: 
 a tray having outer dimensions matched to dimensions of a standard size mattress, said tray consisting of a bottom sheet of compressible material having a surface with an outer periphery, and a plurality of rails of compressible material attached to said outer periphery and forming a substantially rectangular frame with a central, open recess.    
     
     
         2 . A bedding product as claimed in  claim 1  wherein said rails are attached to each other by an attachment selected from the group consisting of glue and double-sided adhesive tape and are adhered to said bottom sheet by an attachment selected from the group consisting of glue and double-sided adhesive tape.  
     
     
         3 . A bedding product as claimed in  claim 1  wherein said compressible material of said bottom sheet is the same as said compressible material of said rails, except as to density.  
     
     
         4 . A bedding product as claimed in  claim 1  wherein at least one of said compressible material of said bottom sheet and said compressible material of said rails consists of foam.  
     
     
         5 . A bedding product as claimed in  claim 1  wherein at least one of said compressible material of said bottom sheet and said compressible material of said rails consists of polyester densified fiber.  
     
     
         6 . A bedding product as claimed in  claim 1  wherein at least one of said inserts is a zoned insert.  
     
     
         7 . A bedding product as claimed in  claim 1  wherein said compressible material of said rails has a higher density than said compressible material of said bottom sheet.  
     
     
         8 . A bedding product comprising: 
 a tray having outer dimensions matched to dimensions of a standard size mattress, said tray consisting of a bottom sheet of compressible material having a surface with an outer periphery, and a plurality of rails of compressible material attached to said outer periphery and forming a substantially rectangular frame with a central, open recess; and    a plurality of inserts, respectively having selected firmness characteristics, disposed in said recess.    
     
     
         9 . A bedding product as claimed in  claim 8  wherein said rails are attached to each other by an attachment selected from the group consisting of glue and double-sided adhesive tape and are attached to said bottom sheet by an attachment selected from the group consisting of glue and double-sided adhesive tape.  
     
     
         10 . A bedding product as claimed in  claim 8  wherein said compressible material of said rails has a higher density than said compressible material of said bottom sheet.  
     
     
         11 . A bedding product as claimed in  claim 8  wherein the inserts in said plurality are attached to each other in succession.  
     
     
         12 . A bedding product as claimed in  claim 8  wherein said inserts are disposed in said recess with no direct attachment to said rails.  
     
     
         13 . A bedding product as claimed in  claim 8  wherein said inserts are attached to each other in succession and are disposed in said recess with no direct attachment to said rails.  
     
     
         14 . A bedding product as claimed in  claim 8  wherein said plurality of inserts includes a bottommost insert, and wherein said bottommost insert is attached to said bottom sheet of said tray.  
     
     
         15 .  4 . A bedding product as claimed in  claim 8  wherein at least one of said compressible material of said bottom sheet and said compressible material of said rails consists of foam.  
     
     
         16 . A bedding product as claimed in  claim 8  wherein at least one of said compressible material of said bottom sheet and said compressible material of said rails consists of polyester densified fiber.  
     
     
         17 . A bedding product as claimed in  claim 8  wherein at least one of said inserts is a zoned insert.  
     
     
         18 . A bedding product as claimed in  claim 8  wherein said inserts are selected from the group consisting of 1½″×½″ CV, 2″×1″ CV, 1½″×¾″ XL 21 ILD CV, 1″ latex, 2″ visco, 1″ XL 21 ILD, ⅞″×⅜″ convoluted foam, 1″ visco.  
     
     
         19 . A method for making a bedding product comprising the steps of: 
 providing a tray consisting entirely of compressible material, having a tray bottom and a rectangular peripheral frame attached to said tray bottom with a central, substantially rectangular opening therein;    inserting a plurality of inserts in said opening, having respectively different firmness characteristics, to produce a bedding product having selected overall bedding product firmness characteristics.    
     
     
         20 . A method as claimed in  claim 19  comprising employing compressible material for said frame having a higher density than said compressible material of said bottom sheet.  
     
     
         21 . A method as claimed in  claim 19  comprising attaching said rails to said bottom sheet by an attachment selected from the group consisting of glue and double-sided adhesive tape.  
     
     
         22 . A method as claimed in  claim 19  comprising attaching said plurality of inserts to each other in succession to form an insert combination, and disposing said insert combination in said recess.  
     
     
         23 . A method as claimed in  claim 22  comprising disposing said insert combination in said recess with no direct attachment to said frame.  
     
     
         24 . A method as claimed in  claim 19  comprising disposing said plurality of inserts in said recess with no direct attachment to said frame.  
     
     
         25 . A method as claimed in  claim 19  comprising employing inserts in said plurality with respectively different firmness characteristics selected from the group consisting of density and compressibility.  
     
     
         26 . A method as claimed in  claim 19  comprising selecting said inserts in said plurality from the group consisting of 1½″×½″ CV, 2″×1″ CV, 1½″×¾″ XL 21 ILD CV, 1″ latex, 2″ visco, 1″ XL 21 ILD, ⅞″×⅜″ convoluted foam, 1″ visco.  
     
     
         27 . A method as claimed in  claim 19  comprising employing foam material as said compressible material for at least one of said tray bottom and said frame.  
     
     
         28 . A method as claimed in  claim 19  comprising employing polyester densified fiber material as said compressible material for at least one of said tray bottom and said frame.  
     
     
         29 . A method as claimed in  claim 19  comprising employing a zoned insert as at least one insert in said plurality of inserts.  
     
     
         30 . A method as claimed in  claim 19  wherein said plurality of inserts includes a bottommost insert, and comprising the step of attaching said bottommost insert to said tray bottom.