000001
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`BEDGEAR 1009
`IPR of U.S. Pat. No. 8,402,580
`
`

`
`U.S. PATENT DOCUMENTS
`
`2,066,428 A
`2,112,892 A
`2,142,336 A
`2,161,448 A
`2,162,755 A
`2,183,828 A
`2,191,956 A
`2,191,963 A
`2,195,039 A
`2,197,188 A
`2,245,779 A
`2,302,259 A
`2,414,927 A
`2,454,463 A
`2,528,313 A
`2,569,627 A
`2,571,543 A
`2,598,141 A
`2,605,483 A
`2,624,893 A
`2,637,049 A
`2,639,444 A
`2,696,872 A
`2,778,412 A
`2,793,683 A
`2,856,615 A
`2,942,280 A
`2,963,715 A
`2,994,094 A
`3,013,283 A
`3,020,566 A
`3,114,156 A
`3,142,072 A
`3,144,666 A
`3,150,621 A
`3,181,179 A
`3,238,748 A
`3,258,942 A
`3,273,175 A
`3,290,702 A
`3,336,644 A
`3,371,668 A
`3,438,068 A
`3,468,748 A
`3,552,154 A
`3,575,782 A
`3,670,345 A
`3,789,441 A
`3,795,019 A
`3,857,124 A
`3,906,559 A
`3,996,633 A
`3,999,233 A
`4,009,597 A
`4,042,986 A
`4,081,301 A
`4,185,341 A
`4,338,693 A
`4,370,939 A
`4,384,380 A
`4,386,439 A
`4,422,195 A
`4,494,262 A
`4,536,028 A
`4,552,795 A
`4,606,964 A
`4,644,598 A
`4,651,370 A
`4,662,013 A
`4,671,568 A
`4,672,702 A
`
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`1/1939 Selinger
`6/1939 Bishop
`5/1939 Shallef
`12/1939 Trubitz
`2/1940 Coldren
`2/1940 London
`3/1940 Shauer
`4/1940 Lilley
`6/1941 Heil
`11/1942 Rothfuss
`1/1947 Chaprnan
`11/1948 Krorner
`10/1950 Kessler
`10/1951 Black
`10/1951 C0I1I10f
`5/1952 Simpson
`8/1952 Ridenhour
`1/1953 Harris
`5/1953 Kromer
`5/1953 De Monsabert
`12/1954 Kurlandetal.
`1/1957 Trubitt
`5/1957 Trubitt
`10/1958 Cirocco
`6/1960 Mayilr.
`12/1960 Young
`8/1961 Hester
`12/1961 Steffinich
`2/1962 Anderson et al.
`12/1963 Cobb
`7/1964 Goodson, Jr.
`8/1964 Mazeraetal.
`9/1964 Warnook
`5/1965 Roddey, Jr.
`3/1966 Yorketal.
`7/1966 Mednick
`9/1966 Andersonetal.
`12/1966 Seltzer
`8/1967 Dusenburyet al.
`3/1968 Johnson
`4/1969 Anderson et al.
`9/1969 Bassett
`1/1971 Lesley
`4/1971 Hansen
`6/1972 Doll et al.
`2/1974 Weiss
`3/1974 Fragas
`12/1974 Hadley
`9/1975 Bahr
`12/1976 Burke
`12/1976 Morris
`3/1977 Wall
`8/1977 Goodman etal.
`3/1978 Buell
`1/1980 Scales
`7/1982 Vitale
`2/1983 Fontcuberta
`5/1983 Glahaetal.
`6/1983 Roccograndiet al.
`12/1983 Russo etal.
`1/1985 Robertson
`8/1985 Jones etal.
`11/1985 Hansen etal.
`8/1986 Wideman
`2/1987 McGuire et al.
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`6/1987 Greer
`6/1987 lshani
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`US 7,398,570 B2
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`4,682,379 A
`4,682,555 A
`4,703,530 A
`4,704,753 A
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`4,756,942 A
`4,757,564 A
`4,773,233 A
`4,731,955 A
`4,801,482 A
`4,841,588 A
`4,876,128 A
`4,879,169 A
`4,899,408 A
`4,937,904 A
`4,952,545 A
`4,980,941 A
`4,935,953 A
`4,993,421 A
`5,003,655 A
`5,027,450 A
`5,029,353 A
`5,041,255 A
`5,042,098 A
`5,046,207 A
`5,055,441 A
`5,075,142 A
`5,127,115 A
`5,131,104 A
`5,133,097 A
`5,155,123 A
`5,177,321 A
`5,249,322 A
`5,271,112 A
`5,287,574 A
`5,325,555 A
`5,513,403 A
`5,530,979 A
`5,542,137 A
`5,603,132 A
`5,625,912 A
`5,636,393 A
`5,809,593 A
`5,996,148 A
`6,164,092 A
`6,272,701 B1
`6,353,947 B1
`5,331,773 131
`6,393,640 B1
`6,463,606 B2
`6,499,157 B1
`6,532,608 B2
`6,704,955 B1
`5,725,477 B2
`6,799,341 B2
`6,823,544 B2
`6,842,921 B1
`6,883,193 B2
`D5l2,869 s
`6,983,500 B2
`6,988,283 B2
`7,003,832 B2
`7,007,325 B1
`2002/0088054 A1
`
`7/1987 Dugan
`7/1987 Bierbaumet al.
`ll/1987 Gusrnan
`11/1937 Lunt
`11/1987 Boggs
`l/1988 VanderWie1eneta1.
`2/1988 Kellogg et al.
`2/1988 Weiss
`3/1988 Joyce
`4/1988 Vitale
`4/1988 Zafiroglu
`5/1988 Morrnan etal.
`5/1933 Dugan
`5/1988 Lunt
`7/1988 Aichele
`7/1988 Goodale
`9/1988 Zafiroglu
`11/1933 Tay1or
`1/1989 Goggans et al.
`6/1989 Harbin etal.
`10/1989 Zafiroglu
`11/1989 Zafiroglu
`2/1990 lllingwonh
`7/1990 Ross
`10/1990 Viiaie
`1/1991 Johnson, 111
`1/1991 Seago
`3/1991 zafiroglu
`4/1991 Kafai
`7/1991 Honig
`7/1991 Kimball etal.
`3/1991 Zafirogiu
`8/1991 Stultz
`9/1991 Chamberlain
`10/1991
`seago
`12/1991 Zafiroglu
`7/1992 Williamsetal.
`7/1992 Larson
`7/1992 Pyles
`11/1992 Horiig
`1/1993 Kawtoski
`10/1993 seago
`12/1993 Bible et 31,
`2/1994 Kardelletal.
`7/1994 Whitley
`5/1996 Wooten, Jr.
`7/1996 Whitley
`3/1995 Byfield
`2/1997 Zafiroglu etal.
`5/1997 McCain etal.
`6/1997 Zafiroglu etal.
`9/1998 Edwards
`12/1999 McCain etal.
`12/2000 Menaker
`8/2001 Zafiroglu
`3/2002 McCain etal.
`5/2002 Peterson
`5/2002 Dalis
`10/2002 Barkeretal.
`12/2002 McCain etal.
`3/2003 Schreiner
`3/2004 Jeffriesetal.
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`10/2004 Wootten, Jr.
`11/2004 Treece
`1/2005 Tsiarkezosetal.
`4/2005 Brooks etal.
`12/2005 Green-Law
`1/2006 Wootten
`1/2006 Griffin
`2/2006 Wilson
`3/2006 Gomeh
`7/2002 McCain etal.
`
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`2003/0056290 Al
`2004/0031100 Al
`2004/0040090 Al
`2004/0163174 Al
`2005/0011007 A1 *
`
`3/2003 Macdonald
`2/2004 Creech
`3/2004 Wootten
`8/2004 Treece
`1/2005 Lintner
`
`2/2005 Te Selle
`2005/0034236 A1 *
`9/2005 Macdonald
`2005/0193490 A1 *
`2005/0284189 A1 * 12/2005 Stewart
`2006/0046591 Al *
`3/2006 Hairston et al.
`
`FOREIGN PATENT DOCUMENTS
`
`DE
`DE
`EP
`
`2800586
`3635417
`425466
`
`* 12/1979
`*
`4/1988
`*
`2/1991
`
`FR
`GB
`GB
`
`2694177
`701899
`891355
`
`*
`*
`*
`
`2/I994
`l/I954
`3/I962
`
`OTHER PUBLICATIONS
`
`Aflidavit of Charles Lohman executed Feb. 27, 2007, including
`Exhibit 1 thereto (comprising a Jacobson’s Home Furnishing Sales
`Catalog Page, a letter dated Jul. 19, 1966 attaching the same, and an
`ad insert entitled “Olde Kentucky Brand Quilted Sidewall Box Spring
`CoVer”).*
`Documents submitted in Perfect Fit U.S. Appl. No. 08/976,718 (now
`USP 5,996,148): “Sack-ette” box spring cover, Perfect Fit Industries,
`Inc. Monroe, NC, 1980, four photocopy sheets.*
`
`* cited by examiner
`
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`Jul. 15,2008
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`US 7,398,570 B2
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`1
`MATTRESS COVER WITH FIT ENHANCING
`COMPOSITE END PANELS
`
`FIELD OF THE INVENTION
`
`The present invention relates to mattress covers, and more
`particularly to fitted mattress covers having a fabric material
`top panel to overlay the top surface of a mattress, and side and
`end panels depending from the top panel for fitting around the
`sides and ends of the mattress. As used herein, the term
`mattress cover is used in its generic sense to mean sheets, and
`covers, e.g., mattress pads used underneath sheets to protect
`the mattress and/or provide a softer surface, and bed spreads
`used over sheets to provide a neat or decorative appearance to
`a bed. The present invention has particularly advantageous
`application to fitted bed sheets.
`
`BACKGROUND OF THE INVENTION
`
`The present inventor has described, in his U.S. Pat. Nos.
`5,249,322; 5,056,441; and 4,985,953, assigned to Louisville
`Bedding Co., fitted mattress coverings which make highly
`advantageous use of a skirt constructed of material which is
`stretchable in its longitudinal dimension, i.e., horizontally
`about the periphery of a mattress upon which it is installed.
`Such a construction provides a firm grip on the mattress to
`thereby prevent shifting of the cover on the mattress during
`use, and to accommodate mattresses of differing thicknesses
`and peripheral dimensions (length and width), while pulling
`the skirt in tightly against and underneath the mattress so as to
`avoid sag or loose fabric otherwise creating a sloppy appear-
`ance.
`
`In one embodiment of the aforementioned Seago patents,
`the depending skirt is formed from a separate strip ofmaterial
`which is attached about the periphery of an inelastic top panel
`ofthe mattress covering, e.g., mattress pad. The separate strip
`comprises a gathered single layer of substantially inelastic
`fabric material with a plurality of spaced-apart parallel, elon-
`gated cords, such as elastic strips or yarn, stitched into the
`inelastic skirt material so as to extend generally perpendicu-
`larly to the longitudinal axes of folds of gathers which form
`with the elastic cords being in a relaxed condition prior to the
`installation of the cover on the mattress.
`
`In another embodiment ofthe above-mentioned Seago pat-
`ents, the skirt comprises side and end panels formed as uni-
`tary extensions of the top panel. These panels are stitched
`together at their ends to form closed corners of the mattress
`cover, and the skirt thus formed is made stretchable by stitch-
`ing into the panels elastic cords under tension, which, when
`permitted to relax, form gathers similar to the first embodi-
`ment.
`
`Mattress pads constructed in accordance with the teachings
`ofthe above-mentioned Seago patents have met with sub stan-
`tial commercial success. The present assignee’s Expand-A-
`Grip® mattress pads, which are covered by the patents, are
`industry leaders. The principles described in the Seago pat-
`ents are fully applicable to fitted sheets as well. However, the
`marketplace adoption of the constructions in sheets has been
`significantly lower.
`This is believed to be due, at least in part, to the sensitivity
`of users and purchasers of bedding products with respect to
`the appearance and feel of a fitted sheet when it is installed
`and used on a mattress. The sides of a fitted sheet installed on
`
`a mattress receive much more exposure, both visually and to
`touch, than do the sides of a fitted mattress pad. Whereas the
`sidewall of a mattress pad generally remains covered by an
`overlying fitted sheet during use, a fitted sheet is revealed
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`upon the drawing back ofa top sheet and blankets or other bed
`coverings. As a result, consumers of bedding products may
`favor a sheet that provides an uninterrupted continuation of
`the sheet material (e.g., a high thread count woven cotton
`fabric) from the main (top) panel to the sidewalls. A fitted
`sheet having its skirt constructed of a separate elasticized strip
`of material attached to and extending about the entire periph-
`ery of a separate top panel would, of course, not provide such
`an uninterrupted continuation of the sheet material.
`The look/feel issue mentioned above may be alleviated
`somewhat with the second one of the above-mentioned
`
`embodiments ofthe Seago patents, since in that embodiment,
`the side panels are provided as integral extensions of the top
`panel. Thus, the construction provides a continuous wrap-
`around ofthe upper edge ofthe mattress, which extends down
`to the first line of stitched-in elastic cord. As illustrated in the
`
`Seago patents, typically this first line of cord would be spaced
`downwardly from the top surface of the mattress. This con-
`struction also has the advantage of forming well defined
`closed corners for neatly fitting the comers of the mattress.
`Nonetheless, the appearance of the lines of stitched-in elastic
`cord may be viewed as an undesirable deviation from the
`conventional uninterrupted extension ofthe main panel mate-
`rial over the full depth of the mattress.
`As a variation on the above-described mattress cover con-
`
`structions of the Seago patents, Whitely U.S. Pat. No. 5,530,
`979, assigned to Perfect Fit Industries, proposes to provide a
`two-part skirt construction. A first upper part of the skirt (an
`inelastic side skirt) is provided as an integral extension of the
`inelastic material used to form the main panel serving to cover
`the mattress top side. A second (lower) part ofthe skirt (elastic
`underskirt) is formed by a strip of material attached to the
`bottom edge of the side skirt about its entire periphery, and is
`made elastically stretchable in its longitudinal dimension,
`i.e., peripherally about a mattress on which it is installed, for
`contraction under a mattress. A variety of known elastically
`stretchable fabric constructions are used to form the second
`
`elastic part.
`In a manner similar to the above-mentioned second
`
`embodiment of the Seago patents, such a construction
`reduces the coverage area of the elastic material, and also
`permits the formation of well-defined closed corners. None-
`theless, a seam attaching the strip of elastic material to the
`inelastic side skirt, as well as the differentiated elastic mate-
`rial itself, will be present and visible along the mattress side-
`walls when the construction is used in a fitted sheet. Thus, the
`aesthetics and touch/feel related drawbacks mentioned above
`
`persist.
`Isham U.S. Pat. No. 4,672,702 discloses a mattress cover-
`ing comprising a main panel provided with mattress sidewall
`covering extensions. These extensions are provided with rect-
`angular cut-outs at their corners. The cut-outs accommodate
`the ends of stretch fit end panels having a length exceeding the
`width of the mattress upon which the cover is to be installed,
`such that when the cover is installed the stretch fit panels wrap
`around the corners ofthe mattress. Each stretch panel is sewn
`along its upper edge to a corresponding end edge of the main
`panel, which in turn lies in registry with an end edge of the
`mattress top surface periphery. The ends of the stretch end
`panels are sewn to corresponding edges of the cut-outs pro-
`vided in the mattress sidewall covering extensions. Isham
`discloses that stretch fabrics suitable for use in forming the
`stretch panels are typically elastic in only one direction, and
`that when such materials are used the rectangular stretch
`panel should be cut such that the stretch takes place along a
`line perpendicular to the panel’s long edge, i.e., to provide
`stretchability in the up and down direction.
`
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`3
`The Isham configuration has the drawback ofnot providing
`significant stretchability in the peripheral direction of the
`skirt. Such peripheral stretchability in a skirt has proven to be
`much more effective than up-down stretch in providing a
`secure grip on a range of mattress sizes and thicknesses.
`Moreover, in the case of a fitted sheet construction, the exten-
`sion of the stretch end panels about the four comers of the
`mattress, into sidewall regions at the head and foot ends ofthe
`bed, detrimentally places differentiated elastic material along
`sidewall areas which are exposed upon the drawing back of a
`top sheet, blanket and/or other bed covering.
`Johnson, III U.S. Pat. No. 4,980,941 discloses a fitted bed-
`ding product wherein portions of side panels thereof are
`formed of elastic material. In particular, Johnson, III teaches
`use of stretch panels formed from a three layer laminate
`construction (with seams extending vertically). One dis-
`closed embodiment
`includes a configuration of corner
`encompassing stretch end panels which appears to be gener-
`ally similar to that disclosed by the Isham patent, including
`the attendant shortcomings.
`Kardell et al. U.S. Pat. No. 5,287,574, shown on its face to
`be assigned to Restful Knights, proposes a fitted mattress
`covering which employs elasticized head and foot panels. An
`upper edge of each panel is secured, by conventional sewing
`methods, to a top portion of a unitary main panel of the
`mattress cover. The ends ofthe head and foot panels are sewn
`to corresponding ends of overhanging first and second side
`portions of the unitary main panel. The elasticized head and
`foot panels are provided in a trapezoidal shape, such that the
`bottom edges ofthe head and foot panels have a shorter length
`than those panels’ top edges. According to the patent, this will
`cause the head and foot panels to exert greater tension on the
`side portions of the main panel near the lower edges thereof,
`to assure a secure fit for a range of mattress thicknesses.
`The Kardell et al. trapezoidal panel configuration, and the
`manner of its attachment to the main panel, are such as to
`induce an elastic recovery force that increases linearly from
`essentially zero at the point of attachment of the top edge
`(where the elastic material is unstretched at the time of being
`bound to the main panel material) to a maximum along the
`bottom edge (where the greatest amount of stretch is required
`to attach the end panels to the ends of the overhanging side
`portions of the main panel). As a result, the ability of the
`mattress covering to grip tightly to the mattress and avoid
`shifting may be compromised, especially at an upper portion
`of the corners of the mattress sidewalls and end walls, where
`loose material may also create a sloppy appearance. Addi-
`tionally, the corner seams may become distorted as a result of
`the non-uniform tension forces, leading to a degraded fit and
`appearance at the corners.
`
`SUMMARY OF THE INVENTION
`
`In a first aspect, the invention is embodied in a fitted mat-
`tress cover including a top panel of material for fitting in
`overlaying relationship to the top surface of a mattress and a
`peripheral skirt depending from the periphery ofthe top panel
`for fitting in overlaying relationship to the sides and ends of
`the mattress. The peripheral skirt includes a pair of extension
`sidewall panels attached to the top panel. The sidewall panels
`are sized and configured to overlie substantially the entire
`sides of the mattress. A pair of extension end panels are
`attached to the top panel. At least one of the extension end
`panels is sized and configured to overlie substantially only an
`upper partial portion of the end walls of the mattress. At least
`one stretch end panel is provided, which is sized and config-
`ured to overlie substantially only a lower partial portion of a
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`corresponding end wall below the upper partial portion. The
`stretch end panel is formed of a stretchable material stretch-
`able in at least a longitudinal direction thereof so as to gen-
`erate an at least partial recovery force. The stretch end panel
`is attached along its upper edge thereof to a corresponding
`peripheral edge of a corresponding one of the extension end
`panels, and is attached at its ends, either directly or indirectly,
`to corresponding end edges ofthe sidewall panels.As a result,
`upon installation ofthe mattress covering on a mattress, the at
`least partial recovery force pulls on the end edges of the
`sidewall panels.
`Such a construction has particularly advantageous appli-
`cation to a fitted sheet, wherein the recovery forces of the
`stretch end panels can be used to effectively grip the mattress
`and thereby minimize shifting of the sheet. At the same time,
`the look and feel of the mattress covering, which may be of
`importance especially in the case of a fitted sheet,
`is
`improved, by virtue of the fact that the side panels can be
`formed as uninterrupted unitary extensions of the material
`forming the top side panel, or other aesthetically dictated
`material, as can upper partial portions (extension end panels)
`of the composite end panels.
`In a second aspect, the invention is embodied in a method
`ofmaking a fitted mattress cover having a top panel for fitting
`in overlaying relationship to a top surface of a mattress and a
`peripheral skirt for overlaying the sides and ends of the mat-
`tress. In the method, a main fabric piece is formed having a
`top panel sized and configured for fitting in overlaying rela-
`tionship to the top surface of a mattress, two opposite exten-
`sion side panels coextensive in length with the top panel so as
`to overlie substantially the entire sides of the mattress, and
`two opposite extension end panels coextensive in length with
`the width of the top panel. At least one of the opposite exten-
`sion end panels is given a depth which is less than a depth of
`the two opposite side panels, so as to overlie substantially
`only an upper partial portion of the endwalls of the mattress.
`At least one stretch end panel is attached along a longitudinal
`edge thereof to a corresponding peripheral edge of a corre-
`sponding one ofthe extension end panels to form a composite
`end panel. The stretch end panel is sized and configured to
`overlie substantially only a lower partial portion of the end
`walls below the upper partial portion. The stretch end panel is
`formed of a stretchable material stretchable in at least a lon-
`
`gitudinal direction thereof so as to generate an at least partial
`recovery force when placed in a stretched condition. Adjacent
`end edges of the composite end panels and side panels are
`attached together to form the peripheral skirt.
`In a third aspect, the invention is embodied in a method of
`imparting mattress gripping stretchability to a mattress cover
`including a top panel of material for fitting in overlaying
`relationship to the top surface of a mattress, and a peripheral
`skirt depending from the periphery of the top panel for fitting
`in overlaying relationship to the sides and ends of the mat-
`tress. The method comprises heat treating at least a portion of
`the peripheral skirt after it has been attached to the top panel,
`to thereby cause the portion of the peripheral skirt to contract
`in a longitudinal direction thereof. This forms a stretchable
`material stretchable in at least a longitudinal direction of the
`skirt. Stretching of the stretchable material generates an at
`least partial recovery force, whereby upon installation of the
`mattress covering the at least partial recovery force causes the
`skirt to grip the mattress.
`The above and other objects, features, aspects and advan-
`tages of the present invention will be readily apparent and
`fully understood from the following detailed description of
`preferred embodiments,
`taken in connection with the
`appended drawings.
`
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`US 7,398,570 B2
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`5
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`FIG. 1 is a comer perspective View of an exemplary mat-
`tress covering (specifically a fitted sheet) in accordance with
`the present invention, installed upon a mattress which is situ-
`ated on top of a box spring or foundation.
`FIG. 2 is an end perspective view of the mattress covering/
`mattress/box spring combination illustrated in FIG. 1.
`FIG. 3 is a bottom plan view of the mattress covering
`illustrated in FIG. 1, and the mattress upon which it
`is
`installed.
`
`FIG. 4 is a plan view depicting the general manner of
`assembly of a main piece of material and two panels of
`stretchable material, to form the exemplary inventive mattress
`covering shown in FIG. 1.
`FIG. 5 is a diagrammatic partial plan view illustrating an
`exemplary method for sewing a stretch end panel to a respec-
`tive extension end panel of the main piece of material, in
`accordance with an aspect of the invention.
`FIG. 6 is a plan view depicting a composite blank of fabric
`material formed by the attachment ofthe stretch end panels to
`the main piece of material as illustrated in FIGS. 4 and 5.
`FIG. 7 is a diagrammatic partial perspective view illustrat-
`ing an exemplary method for closing the corners of a mattress
`covering in accordance with an aspect of the invention.
`
`DETAILED DESCRIPTION OF THE PREFERRED
`EMBODIMENTS
`
`With reference to FIGS. 1, 2 and 3, there is shown an
`example of a fitted mattress cover, and specifically a fittedbed
`sheet 1, in accordance with the present invention. Fitted bed
`sheet 1, which is shown installed on a conventional mattress
`5 (visible in FIG. 3), includes a top panel 3 of generally
`rectangular peripheral shape for fitting in overlaying relation-
`ship to the top surface ofthe mattress. Mattress 5 may sit upon
`a conventional box spring or other mattress foundation 7. A
`peripheral skirt 9 is attached at the peripheral edge of top
`panel 3 and depends therefrom for fitting in overlaying rela-
`tionship to the sides and ends of the mattress. In accordance
`with an aspect of the present invention, peripheral skirt 9 is a
`composite skirt comprising (1) panels formed as unitary
`extensions of top panel 3; and (2) separate stretchable end
`panels.
`In particular, peripheral skirt 9 comprises extension side
`panels 11 that may be integrally formed as unitary parts ofthe
`main piece of material forming top panel 3, and composite
`end panels 13. Composite end panels 13 comprise extension
`end panels 15, that may be formed as integral unitary parts of
`the main piece ofmaterial forming top panel 3, and separately
`formed, attached stretch end panels 17. Stretch end panels 17
`are attached along their respective upper edges to the corre-
`sponding peripheral edges of the extension end panels 15. As
`will be described in further detail, this attachment is effected
`while maintaining the attachment edge of the partial end
`panels under tension in a longitudinally stretched condition.
`As such, upon being permitted to relax, the recovery of the
`stretch material
`to its relaxed state draws the material
`
`inwardly upon itself and carries with it the peripheral edges of
`extension end panels 15.
`Various relative sizes of the extension end panels 15 and
`stretch end panels 17 may be employed, depending, e.g., on
`the overall desired skirt depth and the materials used. In one
`example, where a total skirt depth of approximately 15" is
`provided, approximately 10" may be allocated to the stretch
`end panels and approximately 5" may be allocated to the
`extension end panels (221 ratio).
`
`10
`
`15
`
`20
`
`25
`
`30
`
`35
`
`40
`
`45
`
`50
`
`55
`
`60
`
`65
`
`6
`In an exemplary embodiment, a single piece of material
`forms top panel 3, extension side panels 11, and extension end
`panels 15. That material may be a substantially inelastic and
`substantially non-stretchable material, e.g., of woven cotton
`(traditional muslin). Alternatively, this main piece ofmaterial
`may comprise a stretchable fabric; that fabric may or may not
`comprise elastic threads or cords. For example, the material
`may be of stretchable knitted cotton, of the type commonly
`used for T-shirts. As another possibility, the material could be
`a stretchable knit ofwicking polyester. Regardless ofthe type
`of fabric used for the main piece of material, so long as the
`edges ofthe stretch end panels 17 are longitudinally stretched
`at the time of attachment to the main piece of material, the
`recovery of the stretch panel material following the attach-
`ment will cause the formation of gathers in the extension end
`panels 15 and a contraction of a central portion of top panel 3
`(as generally illustrated in FIG. 6). This permits, at the time of
`installing sheet 1 on a mattress, stretch end panels 17 to
`stretch across their full width and length, without such stretch
`being impeded by the panels’ attachment to the main piece of
`material (particularly extension end panels 15 thereof).
`The stretch ofthe stretch end panels 17, upon installation of
`sheet 1 on mattress 5, sets up recovery forces acting inwardly
`toward the center of the composite end panels 13. At its
`opposite ends, each of composite end panels 13 is attached to
`corresponding end edges of side extension panels 11. Hence,
`the recovery forces (which may be partial recovery forces)
`pull peripherally on side extension panels 11, thereby tending
`to remove any looseness or slack in the side extension panels
`that might otherwise exist by virtue of the mattress covering
`being sized to accommodate mattresses at the upper (as well
`as lower) end of a range of mattress peripheral dimensions
`and thicknesses. The stretch recovery forces transmitted to
`extension side panels 11 also tend to draw in bottom periph-
`eral edge portions 19 of extension side panels 11 underneath
`mattress 5, as well as the bottom peripheral edges of stretch
`end panels 17, as illustrated in FIG. 3, to further improve the
`grip and appearance of the mattress covering.
`In addition, the cap structure formed by extension end
`panels 13, and their corner attachment to extension side pan-
`els 11, further contributes to preventing undesirable shifting
`of the mattress covering on the mattress, by providing well
`defined comers for receiving the comers of the mattress.
`While a similar effective gripping action is achieved with
`mattress covering configurations as described in the afore-
`mentioned Seago patents, this is at some expense with respect
`to the look and feel of the sidewalls and end walls. This is
`
`generally of no consequence for a mattress pad, which will
`typically be covered by a fitted sheet. However, as previously
`mentioned in the Background section, the sidewalls of a fitted
`sheet will typically be exposed to the user(s) of a bed upon the
`drawing back of blanket(s), bed spread(s) and the like. Thus,
`the look and feel of the sidewalls is generally more important
`in this application.
`Advantageously, sheets constructed in accordance with the
`present invention afford the opportunity to maintain, on the
`mattress sidewalls, the same uninterrupted look and feel of
`the top panel of material, since the sidewall covering skirt
`portions can be constructed as uninterrupted continuations of
`the top panels. Moreover, even the end panels (which are
`typically much less likely to be exposed to the user than the
`side panels) can retain in substantial part the same look and
`feel as the top panel by virtue of the fact that the stretch end
`panels may be confined to a lower partial portion ofthe end(s)
`to which they are applied.
`While in the illustrated arrangement the extension side
`panels and extension end panels are formed as unitary exten-
`
`OOOO13
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`

`
`US 7,398,570 B2
`
`7
`sions of top panel 3, the extension side panels and extension
`end panels could instead be pieces of material formed sepa-
`rate from the material of top panel 3, and then attached
`thereto. Even in this case, the present inventive approach
`affords the advantage that aesthetics may dictate what those
`materials may be, since the gripping functionality will be
`achieved with the stretch end panel provided at partial lower
`portions of at least one, and preferably both, ends of the
`mattress. By confining the stretch panel to a smaller area of
`the skirt, it is also possible to realize cost savings, due to the
`potentially higher cost of the stretch material in comparison
`to the material(s) of the remainder of the sheet or other mat-
`tress covering.
`At the same time, sheets and other mattress coverings in
`accordance with the invention can be constructed so as to
`
`exhibit advantageous grip and fit characteristics that rival
`those achieved with the mattress coverings of the aforemen-
`tioned Seago patents. This is due, at least in part, to a method
`of manufacturing a mattress covering in accordance with an
`aspect of the invention, which permits stretch fabrics provid-
`ing a significantly stronger longitudinal pull (recovery) force
`to be employed for the stretch panels, as will be explained.
`As can be seen in FIG. 3, an elastic strip 21 may be attached
`under tension to the distal or bottom peripheral edge of skirt
`9. As such, when fitted sheet 1 is installed on mattress 5,
`elastic strip 21 contributes to the pulling ofthe bottom periph-
`eral skirt edge portion 19 underneath the mattress, as seen in
`FIG. 3.
`
`Various methods may be used to construct a mattress cov-
`ering (sheet, mattress pad, etc.) in accordance with the inven-
`tion. In order to make a mattress cover as illustrated, a sub-
`stantially inelastic non-stretchable fabric material may be cut
`or otherwise formed into a main piece of material providing,
`as illustrated in FIG. 4: top panel 3, sized and configured to
`overlay the top side of a mattress; two opposite extension side
`panels 11, unitary with top panel 3 and coextensive with the
`length of top panel 3 for overlaying the two opposite sides of
`the mattress; and two opposite extension end panels 15 uni-
`tary with the top panel 3 and coextensive with the width ofthe
`top panel 3, for partially overlaying the two opposite ends of
`the mattress. It will be understood, however, that the invention
`is not limited to a unitary main piece ofmaterial as described,
`but rather a main piece of material comprising extension side
`panels and extension end panels may be formed by respective
`panels of material which are separately formed and then
`attached together to form a composite panel structure to
`which the stretch end panels may be attached.
`Now, with reference to FIGS. 4 and 5, a process for attach-
`ing the stretch end panels 17 to corresponding extension end
`panels 15 is described. As diagrammatically depicted in FIG.
`4, the stretch end panels 17 are attached to the corresponding
`extension end panels 15 in a tensioned, stretched state. In
`particular, at least the attachment edge of the elongated panel
`of stretch material forming stretch end panels 17 is main-
`tained under stress or tension in the longitudinal direction as
`the edge of the panel is attached to the edge of panel 15.
`Significantly, it is not necessary to stretch the whole width of
`the stretch panel (top to bottom) during attachment, just the
`edge portion that will comprise the attachment seam.
`The attachment may be effected by sewing, and the sewing
`may be performed by an operator using a conventional serg-
`ing sewing machine. In this case, the tensioning and stretch-
`ing is preferably carried out in an incremental, edgewise
`fashion. Since it is only n