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`BEDGEAR 1012
`IPR of U.S. Pat. No. 8,402,580
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`Patent Application Publication
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`Sep. 8, 2005 Sheet 1 of 4
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`US 2005/0193490 A1
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`FIG. 2
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`Patent Application Publication
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`Sep. 8, 2005 Sheet 2 of 4
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`US 2005/0193490 A1
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`Patent Application Publication
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`Sep. 8, 2005 Sheet 3 of 4
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`US 2005/0193490 A1
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`Patent Application Publication
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`Sep. 8, 2005 Sheet 4 of 4
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`US 2005/0193490 A1
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`FIG. 7
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`US 2005/0193490 A1
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`Sep. 8, 2005
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`TEXTILE CONSTRUCTION
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`[0001] The present invention relates to the field of bed
`linens. In particular, the present invention provides novel
`fitted mattress sheets and pads.
`
`[0002] Mattress pads are coverings applied to mattresses
`generally either to provide additional cushioning, or to
`provide a waterproof surface. Mattress pads may simply sit
`on a mattress; they may be attached by straps at the corners
`of a mattress, or they may be fitted to a mattress. The most
`useful mattress pads are those fitted to a mattress, because
`they do not shift, or become loose or bunched up in use. It
`is especially important with children’s mattress pads to
`ensure a good secure fit, so that a loose pad does not present
`a safety hazard.
`
`[0003] Generally speaking, pads are made by providing a
`rectangular sheet of fabric having a width dimension about
`the same as a given mattress. Asimilarly dimensioned piece
`of batting is aligned on the fabric, and then a second piece
`of fabric, also of the same size, is aligned on the batting. This
`three-layer assembly is then machine quilted together, either
`one piece at a time in mattress size lengths, or in rolls of long
`lengths, to be cut for individual mattresses. A waterproof
`layer may be applied to the underside, or upper surface, if
`desired, by sewing side seams. Individual mattress sized
`pieces are then cut, and provided with side and end panels,
`corners are sewn joining the side and end panels, and elastic
`is applied to finish the exposed edges of the side and end
`panels. If desired, for a better fit, the side and end panels may
`be elasticized.
`
`[0004] The product obtained using the manufacturing
`method outlined above is generally satisfactory, but is very
`labour intensive to make. Moreover, since the only thing
`keeping the pad on a mattress is the elastic, it must be quite
`robust, and therefore expensive.
`
`[0005] The present invention provides a method of making
`fitted mattress pads, and mattress pads made by the method,
`that are an improvement in fit over known pads; but requir-
`ing less labour.
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`[0006] The present invention also provides fitted sheets.
`The fitted sheets of the present invention are characterized in
`that either the end, or the side, panels, thereof, are made
`from a knit fabric, and the remainder of the sheet is made
`from a woven fabric such as a flannel.
`
`invention
`the present
`then,
`In a broad aspect,
`[0007]
`i) a central rectangular
`relates to a mattress pad having:
`panel comprising a plurality of layers including an upper
`textile layer, a lower textile layer, and a batting layer quilted
`to at least one of the upper and lower textile layers; ii) side
`panels depending from said central panel, comprising a
`single layer of a textile fabric; and iii) end panels defined by
`extensions of said central panel; said side panels being
`joined to said end panels by seams extending in a transverse
`direction in relation to said rectangular central panel.
`
`ADDITIONAL STATEMENT OF INVENTION
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`In drawings that illustrate the present invention by
`[0008]
`way of example:
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`[0009] FIG. 1 is an underside view of a mattress pad made
`according to the present invention;
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`[0010] FIG. 2 is a schematic of the manufacturing method
`of the present invention;
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`[0011] FIG. 3 is a perspective view of a mattress pad
`according to the present invention, on a mattress;
`
`[0012] FIG. 4 is a perspective of a fitted bed sheet
`according to another embodiment of the present invention,
`fitted on a mattress;
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`[0013] FIG. 5 is a pattern for the fitted sheet of FIG. 4:
`
`[0014] FIG. 6 is a perspective of a fitted bed sheet
`according to another embodiment of the present invention,
`fitted on a mattress;
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`[0015] FIG. 7 is a pattern for the fitted sheet of FIG. 6.
`
`[0016] Referring to FIG. 1, the present invention provides
`a mattress pad 1 having a central portion that will be about
`the same width w a selected mattress, and will have a length
`equal to the length of a selected mattress, plus about twice,
`or slightly more than twice the depth of such a mattress. Side
`panels 3 at least about 1.2 times the depth to about twice of
`the selected mattress extend from the central panels and are
`folded over the central portion. The top and bottom edges are
`then cut, on a slight curve, and a seam is sewn across each
`of the top and bottom edges. Elastic 5 may be sewn at each
`end of the construction, up one inner side edge of a side
`panel, across the end of the central panel, and down the inner
`side edge of the other side panel. The resultant pad is not
`provided with corners as provided in prior art pads, but
`rather the side panels 3 will extend down the side of a
`mattress, and under it slightly. The ends of the central panel
`2 will cover the ends of the mattress, and the elastic in the
`ends, as well as the slight curvature in the ends, will serve
`to keep the ends of the mattress pad snug on a mattress.
`
`[0017] The side panels 3 may be integral with the central
`panel 2, or they may be sewn thereto by seams extending
`down the side edges 6 of the central panel 2. If the side
`panels are made from a knit fabric with natural stretch
`capabilities, elastic 5 may be eliminated.
`
`[0018] A preferred manufacturing method to make the
`mattress pads of the present invention is shown in FIG. 2.
`A first roll 7 of a textile material 13, that may be woven or
`knit, is unrolled in the direction noted by arrow 12. Slightly
`downstream, a batting 14, which may be cotton, polyester,
`or any other conventional material, is unwound from roll 8
`also in direction 12, aligned with material 13. Another roll
`9 of a textile 15, woven or knit, is unwound, also aligned
`with rolls 7 and 8, so that a three-layer sandwich of
`textile/batting/textile is created. The three-layer sandwich is
`then quilted at the quilting station 16,
`in a conventional
`manner, and continues to proceed in direction 12. A further
`layer, such as a waterproof layer 17, is aligned with the
`quilted construction downstream of quilting station, fed off
`a roll 10. The optional waterproof layer 17 is sewn, along the
`side edges thereof to the quilted construction, and then the
`four layer construction may be wound onto a roll 11.
`
`[0019] At this point, it will be noted that either one of the
`two textile layers 13 or 15 may be wider than the other
`layers, in that it may include side panels 3 integral therewith.
`In such a case, there is no need to sew side panels to the
`textile construction. If, however, it is desired to have side
`panels 3 made from a different material, say a knit fabric
`when the central panel 2 is a woven material, or even if it is
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`US 2005/0193490 A1
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`Sep. 8, 2005
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`panel 30, and therefore made from a woven non-stretch
`material. In such a case the side panels 35 are made from a
`stretch material, sewn along their length to the central panel,
`and joined in the corners to the end panels 34 by seams 36.
`
`1. A mattress pad having:
`
`i) a central rectangular panel comprising a plurality of
`layers including an upper textile layer, a lower textile
`layer, and a batting layer quilted to at least one of the
`upper and lower textile layers;
`
`ii) side panels depending from said central panel, com-
`prising a single layer of a textile fabric; and
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`iii) end panels defined by extensions of said central panel;
`said side panels being joined to said end panels by
`seams extending in a transverse direction in relation to
`said rectangular central panel.
`2. A mattress pad as claimed in claim 1, further compris-
`ing elastic binding on the inside edge of the end portions of
`said side panels, and on the exposed portion of the ends of
`said central panel.
`3. A mattress pad as claimed in claim 1, wherein said side
`panels are 1.2 to 2 times the depth of a selected mattress in
`width.
`
`4. A mattress pad as claimed in claim 3 wherein said
`central panel is about the length of a said selected mattress,
`plus about twice the depth thereof.
`5. A mattress pad as claimed in claim 4, wherein the ends
`of said central panel are arcuate.
`6. A mattress pad as claimed in claim 1, further including
`a waterproof layer.
`7. Amattress pad as claimed in claim 6, wherein a selected
`one of said upper or lower textile layers includes said side
`panels integral therewith.
`8. A fitted sheet comprising:
`
`(i) a central rectangular panel, with said panels integral
`therewith, made from a woven fabric; and
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`(ii) end panels sewn to the ends of said central panel and
`side panels, made from a stretchable fabric.
`9. A fitted sheet comprising:
`
`(i) a central rectangular panel, with end panels integral
`therewith, made from a woven material; and
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`(ii) side panels sewn to the side edges of said central panel
`and end panels, made from a stretchable fabric.
`10. Afitted sheet as claimed in claim 8, wherein the sewn
`seam between said end and central panels is substantially
`horizontal, and the seam between said end and side panels
`is substantially vertical.
`11. Afitted sheet as claimed in claim 9, wherein the sewn
`seam between said end and central panels is substantially
`horizontal, and the seam between said end and side panels
`is substantially vertical.
`*
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`simply desired to have the side panels having a different
`visual appeal than the central panel the side panels may be
`sewn to the construction at the same time as the waterproof
`layer, using the same side seams. In that case, side panel
`material will be fed off two rolls of material 18 to meet the
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`the same point as the waterproof
`construction at about
`material 17. Alternatively, the side panel material may be
`sewn to the central panel 2 by hand, in two pieces, during
`final assembly.
`
`[0020] After the textile construction is wound onto roll 11,
`it is subsequently unwound when desired, and in four steps
`fabricated into fitted bed pads. First, the construction is cut
`at station 19, into correct lengths, about the length of a
`selected mattress plus twice the depth (or slightly more)
`Then, the side panels are folded over, at station 20, and then
`an arcuate seam 4 is sewn across each end. As the seam 4 is
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`sewn, the edge will also be cut by a blade in the sewing
`machine, in a conventional manner. It will be understood
`that for greater efficiency, if the side panels are folded over
`before the cutting process, the cutting and sewing may be
`done in a single step. Moreover, it will be understood that
`winding the construction onto a roll 11 is not necessary if the
`mill is equipped to cut, fold and sew the construction as it
`is fabricated.
`
`[0021] After end seams 4 are sewn, elastic 5 may be
`applied to each end. As illustrated, elastic 5 may be applied
`along the inside edge 23 of side panel 3 near each end edge,
`across the end edge, and down the adjacent inside edge 2:3
`of the opposite side panel.
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`[0022] The resultant bed pad should be turned inside-out
`to hide exposed seams, and will fit on a mattress as shown
`in FIG. 3, with the side panels under the mattress for the full
`length of the mattress. The side panels may be from about
`1.2 to 2 times the depth of the mattress, for a proper fit. As
`shown in FIG. 3, the curvature of the end seams helps to
`ensure a fairly flat fit at each end of the mattress.
`
`[0023] Referring now to FIGS. 4 and 5, a further embodi-
`ment of the present invention is illustrated. In this embodi-
`ment, a central panel 30 has side panels 31 integral there-
`with, the central 30 and side 31 panels being made from a
`non-stretch fabric such as cotton flannelette. Any woven
`fabric may be used, though. Moreover, the integral central
`and side panels may be laminated with, or coated with, a
`waterproof layer, such as PVC.
`
`[0024] End panels 32 of a stretch material such as a knit
`fabric are sewn to the ends of the central panel, and then
`corner seams 33 are sewn between the and panels 32 and the
`side panels 31. The elastic nature of the end panel results in
`a fitted sheet that fits snugly on a mattress. The end and side
`panels will, therefore, be of a width equal to or greater than
`(by a factor of up to about 0.1-0.5) the depth of a selected
`mattress.
`
`It will also be appreciated that, as shown in FIGS.
`[0025]
`6 and 7, the end panel 34 may be integral with the central
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`*
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