Coverings for Viscoelastic Foam Mattresses

Abstract

Covers for mattresses having a reclining surface of viscoelastic foam have a fabric body with a first surface disposed in engagement with the reclining surface; an opposite, second surface disposed for engagement by a person reclining upon the cover; and at least one air flow region defined by the fabric body for enhanced circulation of air between the reclining surface of viscoelastic foam and an opposed skin surface of the person reclining upon the cover.

1 . A cover for a mattress having a reclining surface of viscoelastic foam, the cover comprising:
 a circular knit fabric body having four-way stretch and defining:   a first pile surface disposed in engagement with the reclining surface;   an opposite, second pile surface disposed for engagement by a person reclining upon the cover with the first surface disposed in engagement with the reclining surface; and   at least one air flow region for enhanced circulation of air between the reclining surface of viscoelastic foam and an opposed skin surface of the person reclining upon the cover.   
   
   
       2 . The cover for a mattress having a reclining surface of viscoelastic foam of  claim 1 , wherein at least one of said first pile surface and said second pile surface defines one or more regions with relatively high pile disposed among one or more regions of relatively low pile or no pile, with the one or more regions of relatively low pile or no pile defining the at least one air flow region for enhanced circulation of air between the reclining surface of viscoelastic foam and an opposed skin surface of the person reclining upon the cover. 
   
   
       3 . The cover for a mattress having a reclining surface of viscoelastic foam of  claim 2 , wherein the one or more regions with relatively high pile and the one or more regions of relatively low pile or no pile are arranged upon at least one of said first pile surface and said second pile surface by engineered body mapping techniques in a manner to position the at least one air flow region for enhanced circulation of air between the reclining surface of viscoelastic foam and an opposed skin surface of the person reclining upon the cover in accordance with requirements of corresponding body regions of the person reclining upon the cover. 
   
   
       4 . The cover for a mattress having a reclining surface of viscoelastic foam of  claim 2 , wherein the one or more regions with relatively high pile and the one or more regions of relatively low pile or no pile are arranged upon at least one of said first pile surface and said second pile surface by standard knitting design techniques in a manner to position the at least one air flow region for enhanced circulation of air generally between the reclining surface of viscoelastic foam and an opposed skin surface of the person reclining upon the cover in a regular pattern. 
   
   
       5 . The cover for a mattress having a reclining surface of viscoelastic foam of  claim 3  or  claim 4 , wherein contrasting height among regions of relatively high pile and regions of relatively low pile or no pile is established by contrasting height of sinker loops. 
   
   
       6 . The cover for a mattress having a reclining surface of viscoelastic foam of  claim 5 , wherein said circular knit fabric body comprises stitch yarn with spandex. 
   
   
       7 . The cover for a mattress having a reclining surface of viscoelastic foam of  claim 5 , wherein said circular knit fabric body comprises stretch stitch yarn. 
   
   
       8 . The cover for a mattress having a reclining surface of viscoelastic foam of  claim 5 , wherein said sinker loops of said at least one of said first pile surface and said second pile surface are in unnapped yarn form. 
   
   
       9 . The cover for a mattress having a reclining surface of viscoelastic foam of  claim 5 , wherein said sinker loops of said at least one of said first pile surface and said second pile surface are in napped, velour form. 
   
   
       10 . The cover for a mattress having a reclining surface of viscoelastic foam of  claim 5 , wherein said sinker loops of said at least one of said first pile surface and said second pile surface are in cut loop form without pre-napping. 
   
   
       11 . The cover for a mattress having a reclining surface of viscoelastic foam of  claim 5 , wherein the circular knit fabric body comprises hydrophilic fibers. 
   
   
       12 . The cover for a mattress having a reclining surface of viscoelastic foam of  claim 5 , wherein the circular knit fabric body comprises material selected from the group consisting of cotton and wool. 
   
   
       13 . The cover for a mattress having a reclining surface of viscoelastic foam of  claim 5 , wherein the circular knit fabric body comprises fibers of synthetic material. 
   
   
       14 . The cover for a mattress having a reclining surface of viscoelastic foam of  claim 13 , wherein the synthetic material is selected from the group consisting of polyester; nylon; acrylic; polyester, nylon or acrylic that has been rendered hydrophilic; and blends thereof. 
   
   
       15 . The cover for a mattress having a reclining surface of viscoelastic foam of  claim 1  or  claim 2 , wherein the circular knit fabric body has chemical treatment for one or more properties selected from the group consisting of wicking enhancement, stain release, water repellency, stain repellency, antimicrobial properties, and oil repellency. 
   
   
       16 . The cover for a mattress having a reclining surface of viscoelastic foam of  claim 15 , wherein said fabric body comprises hydrophilic fibers. 
   
   
       17 . The cover for a mattress having a reclining surface of viscoelastic foam of  claim 1  or  claim 2 , wherein said fabric body comprises a fabric laminate. 
   
   
       18 . The cover for a mattress having a reclining surface of viscoelastic foam of  claim 2 , wherein said one or more regions of relatively high pile comprises a plurality of spaced-apart pile pillars and said one or more regions of relatively low pile or no pile comprises intersecting channels extending among said pile pillars and defining said at least one air flow region for enhanced circulation of air between the reclining surface of viscoelastic foam and an opposed skin surface of the person reclining upon the cover. 
   
   
       19 . The cover for a mattress having a reclining surface of viscoelastic foam of  claim 18 , wherein said fabric body comprises a double bar raschel warp knit construction. 
   
   
       20 . The cover for a mattress having a reclining surface of viscoelastic foam of  claim 18 , wherein said fabric body comprises a knit with about 16 to about 28 wales per inch. 
   
   
       21 . The cover for a mattress having a reclining surface of viscoelastic foam of  claim 18 , wherein said fabric body comprises a knit structure with about 14 courses to about 36 courses per inch. 
   
   
       22 . The cover for a mattress having a reclining surface of viscoelastic foam of  claim 18 , wherein yarns of said fabric body have fineness in a range of about 40 to about 600 denier. 
   
   
       23 . The cover for a mattress having a reclining surface of viscoelastic foam of  claim 18 , wherein yarns of said fabric body comprise individual fibers having fineness in a range of about 1 dpf to about 12 dpf. 
   
   
       24 . A cover for a mattress having a reclining surface of viscoelastic foam, said cover comprising:
 a fabric body defining:
 a first surface disposed in engagement with the reclining surface; 
 an opposite, second surface disposed for engagement by a person reclining upon the cover; and 
 at least one air flow region for enhanced circulation of air between the reclining surface of viscoelastic foam and an opposed skin surface of the person reclining upon the cover. 
   
   
   
       25 . The cover for a mattress having a reclining surface of viscoelastic foam of  claim 24 , wherein said fabric body comprises a first fabric layer defining said first surface and a second fabric layer defining said opposite, second surface, with said at least one air flow region defined therebetween; and
 said fabric body further comprises a plurality of intermediate members extending generally between the first fabric layer and the second fabric layer and through said at least one air flow region for enhanced circulation of air between the reclining surface of viscoelastic foam and an opposed skin surface of the person reclining upon the cover.   
   
   
       26 . The cover for a mattress having a reclining surface of viscoelastic foam of  claim 25 , wherein said plurality of intermediate members are disposed to resiliently urge apart said first fabric layer and said second fabric layer. 
   
   
       27 . The cover for a mattress having a reclining surface of viscoelastic foam of  claim 25 , wherein the first fabric layer is permeable to water vapor and impermeable to liquid water. 
   
   
       28 . The cover for a mattress having a reclining surface of viscoelastic foam of  claim 25 , wherein each of the first fabric layer and the second fabric layer comprises stitch yarn. 
   
   
       29 . The cover for a mattress having a reclining surface of viscoelastic foam of  claim 28 , wherein the stitch yarn of the first fabric layer has fineness in a range of about 50 to about 600 denier 
   
   
       30 . The cover for a mattress having a reclining surface of viscoelastic foam of  claim 28 , wherein the stitch yarn of the first fabric layer has individual fiber fineness in the range of about 0.3 to about 6.0 dpf. 
   
   
       31 . The cover for a mattress having a reclining surface of viscoelastic foam of  claim 28 , wherein the stitch yarn of the first fabric layer comprises hydrophilic fibers. 
   
   
       32 . The cover for a mattress having a reclining surface of viscoelastic foam of  claim 28 , wherein the stitch yarn of the first fabric layer comprises fibers of synthetic material. 
   
   
       33 . The cover for a mattress having a reclining surface of viscoelastic foam of  claim 32 , wherein the synthetic material is selected from the group consisting of polyester; acrylic; nylon; polyester, acrylic or nylon that has been rendered hydrophilic; and blends thereof. 
   
   
       34 . The cover for a mattress having a reclining surface of viscoelastic foam of  claim 28 , wherein the stitch yarn of the second fabric layer comprises natural fibers. 
   
   
       35 . The cover for a mattress having a reclining surface of viscoelastic foam of  claim 34 , wherein the stitch yarn of the second fabric layer comprises material selected from the group consisting of cotton and wool. 
   
   
       36 . The cover for a mattress having a reclining surface of viscoelastic foam of  claim 28 , wherein the second fabric layer further comprises lay-in yarn held by the stitch yarn. 
   
   
       37 . The cover for a mattress having a reclining surface of viscoelastic foam of  claim 36 , wherein the lay-in yarn comprises an elastomeric yarn. 
   
   
       38 . The cover for a mattress having a reclining surface of viscoelastic foam of  claim 37 , wherein the lay-in yarn comprises total fineness in a range of about 70 to about 300 denier. 
   
   
       39 . A method of forming a cover for a mattress having a reclining surface of viscoelastic foam, the cover, said method comprising the steps of:
 forming a circular knit fabric having four way stretch, with a first pile surface and an opposite, second pile surface and defining at least one air flow region for enhanced circulation of air between the reclining surface of viscoelastic foam and an opposed skin surface of the person reclining upon the cover; and   forming the circular knit fabric into a cover for a mattress having a reclining surface of viscoelastic foam.