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. The circular knit fabric body comprises a flame retardant material.

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; 
   wherein the circular knit fabric body comprises a flame retardant material.   
   
   
       2 . The cover of  claim 1 , wherein the circular knit fabric body comprises a stitch yarn including the flame retardant material, the flame retardant material comprising a flame retardant fiber. 
   
   
       3 . The cover of  claim 2 , wherein the stitch yarn comprises a blend of natural fiber and the flame retardant fiber. 
   
   
       4 . The cover of  claim 2 , wherein the stitch yarn forms a fire barrier that inhibits flames from passing across the circular knit fabric body from the second pile surface toward the mattress. 
   
   
       5 . The cover of  claim 2 , wherein the flame retardant fiber comprises at least one of fiber containing silicate, melamine resin, carbon fiber, and fiberglass. 
   
   
       6 . The cover of  claim 2 , wherein the flame retardant fiber is blended with an other flame retardant fiber. 
   
   
       7 . The cover of  claim 6 , wherein the other flame retardant fiber is selected from the group consisting of p-aramid, m-aramid, modacrylic, flame retardant Rayon, flame retardant polyester, Polybenzimidazole, and blends thereof. 
   
   
       8 . The cover of  claim 1 , wherein the fabric body comprises a pile yarn, the pile yarn comprising a flame retardant fiber. 
   
   
       9 . The cover of  claim 8 , wherein the flame retardant fiber is blended with an other, non-flame retardant fiber. 
   
   
       10 . The cover of  claim 1 , wherein the flame retardant material comprises a flame retardant fiber formed of inherent flame retardant material. 
   
   
       11 . The cover of  claim 1 , wherein the flame retardant material comprises yarns comprising flame retardant fiber formed of inherent flame retardant material blended with an other, non-flame retardant fiber. 
   
   
       12 . The cover of  claim 1 , 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. 
   
   
       13 . The cover of  claim 12 , wherein the fabric body comprises hydrophilic fibers. 
   
   
       14 . The cover of  claim 1 , wherein the fabric body comprises a fabric laminate. 
   
   
       15 . The cover of  claim 1 , wherein at least one of the first pile surface and the 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. 
   
   
       16 . The cover of  claim 15 , 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 the first pile surface and the 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. 
   
   
       17 . The cover of  claim 16 , 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. 
   
   
       18 . The cover of  claim 15 , 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 the first pile surface and the 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. 
   
   
       19 . The cover of  claim 18 , 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. 
   
   
       20 . The cover of  claim 19 , wherein the circular knit fabric body comprises stitch yarn with spandex. 
   
   
       21 . The cover of  claim 19 , wherein the circular knit fabric body comprises stretch stitch yarn. 
   
   
       22 . The cover of  claim 19 , wherein the sinker loops of the at least one of the first pile surface and the second pile surface are in un-napped yarn form. 
   
   
       23 . The cover of  claim 19 , wherein the sinker loops of the at least one of the first pile surface and the second pile surface are in napped, velour form. 
   
   
       24 . The cover of  claim 19 , wherein the sinker loops of the at least one of the first pile surface and the second pile surface are in cut loop form without pre-napping. 
   
   
       25 . The cover of  claim 19 , wherein the circular knit fabric body comprises hydrophilic fibers. 
   
   
       26 . The cover of  claim 19 , wherein the circular knit fabric body comprises material selected from the group consisting of cotton and wool. 
   
   
       27 . The cover of  claim 1 , wherein the circular knit fabric body comprises cellulosic fibers. 
   
   
       28 . The cover of  claim 19 , wherein the circular knit fabric body comprises fibers of synthetic material. 
   
   
       29 . The cover of  claim 28 , 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. 
   
   
       30 . The cover of  claim 15 , wherein the one or more regions of relatively high pile comprises a plurality of spaced-apart pile pillars and the one or more regions of relatively low pile or no pile comprises intersecting channels extending among the pile pillars and 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. 
   
   
       31 . The cover of  claim 30 , wherein the fabric body comprises a double bar raschel warp knit construction. 
   
   
       32 . The cover of  claim 30 , wherein the fabric body comprises a knit with about 16 to about 28 wales per inch. 
   
   
       33 . The cover of  claim 30 , wherein the fabric body comprises a knit structure with about 14 courses to about 36 courses per inch. 
   
   
       34 . The cover of  claim 30 , wherein yarns of the fabric body have fineness in a range of about 40 to about 600 denier. 
   
   
       35 . The cover of  claim 30 , wherein yarns of the fabric body comprise individual fibers having fineness in a range of about 1 dpf to about 12 dpf. 
   
   
       36 . A cover for a mattress having a reclining surface of viscoelastic foam, the 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; 
   wherein the circular knit fabric body comprises a flame retardant material.   
   
   
       37 . The cover of  claim 36 , wherein the circular knit fabric body comprises a stitch yarn including the flame retardant material, the flame retardant material comprising a flame retardant fiber. 
   
   
       38 . The cover of  claim 37 , wherein the stitch yarn comprises a blend of natural fiber and the flame retardant fiber. 
   
   
       39 . The cover of  claim 37 , wherein the flame retardant fiber comprises at least one of cellulosic fiber containing silicate, melamine resin, carbon fiber, and fiberglass. 
   
   
       40 . The cover of  claim 37 , wherein the flame retardant fiber is blended with an other flame retardant fiber. 
   
   
       41 . The cover of  claim 40 , wherein the other flame retardant fiber is selected from the group consisting of p-aramid, m-aramid, modacrylic, flame retardant Rayon, flame retardant polyester, Polybenzimidazole, and blends thereof. 
   
   
       42 . The cover of  claim 36 , wherein the fabric body comprises a pile yarn, the pile yarn comprising a flame retardant fiber. 
   
   
       43 . The cover of  claim 42 , wherein the flame retardant fiber is blended with an other, non-flame retardant fiber. 
   
   
       44 . The cover of  claim 36 , wherein the fabric body comprises a pile yarn, the pile yarn comprising a non-flame retardant fiber. 
   
   
       45 . The cover of  claim 36 , wherein the flame retardant material is selected from the group consisting of m-aramid, modacrylic, flame retardant Rayon, flame retardant polyester, p-aramid, Polybenzimidazole, and blends thereof. 
   
   
       46 . The cover of  claim 36 , wherein the fabric body comprises a first fabric layer defining the first surface and a second fabric layer defining the opposite, second surface, with the at least one air flow region defined therebetween; and
 the fabric body further comprises a plurality of intermediate members extending generally between the first fabric layer and the second fabric layer and through 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.   
   
   
       47 . The cover of  claim 46 , wherein the plurality of intermediate members are disposed to resiliently urge apart the first fabric layer and the second fabric layer. 
   
   
       48 . The cover of  claim 46 , wherein the first fabric layer is permeable to water vapor and impermeable to liquid water. 
   
   
       49 . The cover of  claim 46 , wherein each of the first fabric layer and the second fabric layer comprises stitch yarn. 
   
   
       50 . The cover of  claim 49 , wherein the stitch yarn of the first fabric layer has fineness in a range of about 50 to about 600 denier. 
   
   
       51 . The cover of  claim 49 , wherein the stitch yarn is a spun yarn having an overall denier in the range of about 50 denier to about 600 denier. 
   
   
       52 . The cover of  claim 49 , 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. 
   
   
       53 . The cover of  claim 49 , wherein the stitch yarn of the first fabric layer comprises hydrophilic fibers. 
   
   
       54 . The cover of  claim 49 , wherein the stitch yarn of the first fabric layer comprises fibers of synthetic material. 
   
   
       55 . The cover of  claim 54 , 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. 
   
   
       56 . The cover of  claim 49 , wherein the stitch yarn of the second fabric layer comprises natural fibers. 
   
   
       57 . The cover of  claim 56 , wherein the stitch yarn of the second fabric layer comprises material selected from the group consisting of cotton and wool. 
   
   
       58 . The cover of  claim 49 , wherein the second fabric layer further comprises lay-in yarn held by the stitch yarn. 
   
   
       59 . The cover of  claim 58 , wherein the lay-in yarn comprises an elastomeric yarn. 
   
   
       60 . The cover of  claim 59 , wherein the lay-in yarn comprises total fineness in a range of about 70 to about 300 denier. 
   
   
       61 . A method of forming a cover for a mattress having a reclining surface of viscoelastic foam, the cover, the 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;   wherein the circular knit fabric body comprises a flame retardant material.