Mattresses, methods of manufacture and components

Abstract

Mattress coverings are manufactured utilizing conventional equipment and using a dummy mattress core. The mattress coverings include a zippered access on the bottom panel, for example, where the dummy core can be removed after the mattress covering is completed. When shipped to a regional assembly facility the zippered access is utilized for insertion of a select mattress core that corresponds to the size of the dummy mattress core about which the mattress covering was assembled. The zippered access is zipped shut and the mattress is ready for sale, transport, and use. Great efficiencies are available where the mattress cover is assembled in a first location, shipped to a sale and use location and also regionally close to where mattress cores are manufactured, and the mattress covers are assembled with cores into mattresses.

Claims

1. A stack or compilation of completed and empty quilted mattress coverings for subsequent assembly with respective mattress cores for providing completed mattresses for retail sale, each of the mattress coverings comprising: a quilted top panel component having a periphery, the quilted top panel component comprising a top exterior fabric panel with a peripheral edge portion, a thin interior fabric panel with a peripheral edge portion, at least one foam layer with a peripheral edge and at least one low density fiber layer sandwiched between the exterior fabric panel and the thin interior fabric panel, the quilted top panel having an ordered arrangement of connections extending through the top panel thereby securing together the top exterior fabric panel, the thin interior fabric panel, the at least one foam layer, and the at least one low density fiber layer; a quilted sidewall border component extending around the entire periphery, the quilted sidewall border component comprising an exterior fabric strip with an upper edge portion and a lower edge portion, a thin interior fabric strip with an upper edge portion and a lower edge portion, a foam or fiber layer strip sandwiched between the exterior fabric strip and the thin interior fabric strip, the quilted sidewall border component secured to the quilted top panel component by tape edge extending about and sewn to the top exterior fabric panel peripheral edge portion, the thin interior fabric panel peripheral edge portion, the upper edge portion of the exterior fabric strip, and the upper edge portion of the interior thin fabric strip; and a thin bottom fabric panel with an edge portion, the bottom fabric panel joined to the quilted sidewall border component by tape edge extending about and sewn to the thin bottom panel edge portion, the lower edge portion of the exterior fabric strip, and the lower edge portion of the thin interior fabric strip; wherein the thin interior fabric panel of the quilted top panel component, the thin interior fabric strip of the quilted sidewall border component, and the thin bottom fabric panel of each quilted mattress covering define a mattress core receiving pocket sized to a common dummy core, and wherein the thin bottom fabric panel of each quilted mattress covering has a zipper extending along a plurality of four sides of a periphery of the thin bottom fabric panel for accessing the empty mattress core receiving pocket, and wherein each quilted mattress covering having five closed sides and one side openable and closeable with a zipper, wherein each of the quilted mattress coverings are sized by the dummy core, and wherein the dummy core is completely coverable by each of the quilted mattress coverings.

2. The stack or compilation of mattress coverings of claim 1, wherein the compilations or stacks are enclosed in a shipping container.

3. The stack or compilation of mattress coverings of claim 1, wherein each mattress covering is vacuum packed.

4. The stack or compilation of mattress coverings of claim 1, wherein each of the mattress coverings have a transportation configuration, a final assembly configuration, and a use configuration, such that in the transportation configuration the singular sidewall border component folds in upon itself defining a flattened and/or folded minimal volume state having a maximum thickness of less than 6 inches, in the filling configuration the zipper is an in open position and a portion of the material panel is pulled back, and in the use configuration the mattress core is located within the cavity and the zipper is in a sealed position.

5. A method of making a plurality of mattresses comprising: for each of the quilted mattress coverings of claim 1, sewing the tape edge joining the quilted top panel to the quilted sidewall border utilizing the dummy core and a tape edge machine; and for each of the quilted mattress coverings of claim 1, sewing the tape edge joining the bottom fabric panel to the quilted sidewall border utilizing the dummy core and the tape edge machine.

6. The method of claim 5, further comprising: receiving the stack or compilation of quilted mattress coverings; removing one of the mattress coverings from the stack of mattress; unfolding the one mattress coverings; unzipping the zipper of the one mattress covering if it is zipped; inserting a pocketed spring core into the one mattress covering; and zipping the zipper of the one mattress covering.

7. The method of claim 6, further comprising: repeating the steps of the method of claim 6 thereby producing a subsequent mattress; and placing the subsequent mattress atop a previously produced mattress.

8. The method of claim 7, further comprising bagging each of said mattresses.

9. The stack of compilation of quilted mattress coverings of claim 1, wherein the dummy core is a polymer dummy core.

Description

DESCRIPTION OF THE FIGURES

(1) FIG. 1A is a top perspective view of a mattress according to embodiments.

(2) FIG. 1B is a cross sectional view of a portion of the mattress of FIG. 1.

(3) FIG. 2 is a perspective view of a dummy mattress core according to embodiments.

(4) FIG. 3 is a prior art piece of textile or sheet material cutting equipment.

(5) FIG. 4 is a perspective view of a generic prior art quilting machine for assembling top panel components of mattresses.

(6) FIG. 5 is a perspective view of a generic prior art quilting machine for manufacturing quilted sidewall border components.

(7) FIG. 6 is a perspective view of a generic prior art sewing machine.

(8) FIG. 7 is an illustrated sequence of manufacturing steps for a mattress cover according to embodiments.

(9) FIG. 8 is an illustrated sequence of manufacturing steps for a pillow top mattress cover according to embodiments.

(10) FIG. 9 is an illustrated sequence of assembly steps for a mattress from the mattress covers herein.

(11) FIG. 10 is a diagrammatic illustration of utilizing the mattress covers in the chain of commerce of mattresses.

(12) FIG. 11 is a diagrammatic illustration of utilizing the mattress covers in the chain of commerce of mattresses.

(13) FIG. 12 is a diagrammatic illustration of utilizing the mattress covers in the chain of commerce of mattresses.

DETAILED DESCRIPTION

(14) Referring to FIGS. 1A and 1B, a mattress 20 in accord with embodiments has a mattress cover 21 and a mattress core 22. The mattress cover has a quilted top panel component 24, a quilted sidewall border component 26, and a bottom exterior thin fabric panel 28. The bottom exterior thin fabric panel has a zipper 30. Generally, the mattress has a top side 34, a bottom side 36, two lateral sides 38, 39, a head side 40, a foot side 42, an upper peripheral mattress corner 43, and a lower peripheral mattress corner 44 and generally a periphery 45. Accordingly, the mattress has an exposed top side surface 34.5, an exposed bottom side surface 36.5, exposed lateral side surfaces 38.5, 39.5, an exposed head side surface 40.5, and an exposed foot side surface 42.5. Typically, there is no differentiation between the head side and the foot side. The quilted sidewall border component 26 has an exterior fabric panel or strip 46, an interior thin fabric panel or strip 48, and a layer of foam 50 sandwiched between the exterior fabric and the interior thin fabric. The quilted sidewall border component may be held together by adhesives and/or stitching 52 extending through the quilting. Quilted sidewall border components 26 may be manufactured by specific equipment 53 dedicated to same, see prior art FIG. 5. Typically, a single sidewall border component panel or strip will extend around the entirety of the periphery 20.2 of the mattress providing a singular sidewall border component.

(15) Referring still to FIGS. 1A and 1B, the quilted top panel component 24 generally has a top panel component edge portion 24.3, and comprises an exterior fabric panel 56 with an exterior panel edge portion 56.3, a layer of low density fiber 58, a first foam layer 62, a second foam layer 63, a thin interior fabric panel 64 with a fabric panel edge portion 64.3. Such quilted top panel components may be formed by conventional prior art equipment 67 such as is shown in prior art FIG. 4. The panels of fabric, fiber, foam or other cushioning material may be cut to size by conventional prior art equipment 69 as shown in prior art FIG. 3. The interior panels may be selectively sized to be slightly less area-wise than the exterior fabric panel 56 and the interior fabric panel 64 or may be the same size. Referring again to FIGS. 1A and 1B, below the quilted top panel component 24 is a first core foam layer 72, and a second core foam layer 74. Therebelow is a mattress core 75 illustrated as a pocket spring core having steel springs 77 contained in fabric pockets 78. A non-woven felt layer 80 may be positioned between the mattress core 75 and the bottom exterior thin fabric panel.

(16) The upper peripheral mattress corner 43 and lower peripheral mattress corner 44 are formed by a conventional tape edge 84 that captures the quilted top panel component 24 at a top edge portion and the sidewall border component 26 forming the upper mattress corner 43 and captures the thin exterior fabric panel 29 and the quilted sidewall border component 26 at the lower corner 44. The tape edge 84 may be applied with a conventional tape edge equipment. For the lower corner with less layers to secure, a conventional sewing machine 88 as illustrated in prior art FIG. 6 may be utilized. For clarity of illustration, the tape edge 84 is shown spaced from the edge portions secured therein. In practice the tape edge and edge portions therein are tightly sewn together.

(17) The equipment of FIGS. 3-6 may be in a conventional mattress factory. An additional piece of conventional mattress manufacturing equipment is the tape edge machine 90 as shown in FIGS. 7 and 8. In embodiments, select equipment of Prior Art FIGS. 3-6 are located in a mattress cover factory that assemble the covers utilizing dummy cores and ships covers without a mattress core therein.

(18) Referring to FIGS. 3 and 7, a sequence of manufacture of a mattress cover in such a mattress cover manufacturing facility is illustrated. First a half cap is assembled from quilted sidewall border component 26 sewn with tape edge to a lower exterior thin fabric panel 28 having a zipper installed therein. A dummy core 100, which is not intended to remain in the mattress cover, is installed in the pocket 104. The dummy core may be an actual spring core as shown in FIG. 7 or may be a correspondingly shaped 3 dimensional form, see FIG. 3, made of polymer or other suitable material. The dummy core may be an inflated form or filled with light weigh foam. In embodiments, the dummy core will weigh less than 10 lbs. (or 4.54 kilograms). In embodiments, the dummy core will weigh less than 6 lbs. (or 2.7 kilograms). In embodiments, the dummy core may be slightly dimensionally different that the actual core to be installed in the mattress cover. For example the dummy core may be smaller that the final core to be inserted into the mattress cover allowing a tighter fitting cover than a conventional mattress cover that is manufactured by sewing the mattress cover onto the actual core of the mattress. Note for illustration purposes the open mattress covers for receiving mattress cores appear self supporting; although quilted borders may have some capability of staying upright, generally the covers will need to be manually opened for insertion of mattresses. Also, the coverings may be applied over the core on a table to be fitted around the core and then have the core with cover thereon flipped over so that the open zippered opening may be zipped shut.

(19) A quilted top panel component 24, which may have an ordered arrangement of fasteners 101 extending therethrough, is placed on the core and utilizing a tape edge machine 90 is attached to the quilted sidewall border component 26. The assembly is flipped over as indicated by the arrow 107, such that the bottom exterior thin fabric panel with the zipper is facing upwardly. The zipper 30 is opened, the flap 110 is pulled out of the way, and the dummy core 100 is removed. The mattress cover 21 may be zipped up and folded into a shipping configuration 114, with the sidewall border component 26 folded inwardly to be horizontal and in an overlaying and underlaying relationship with the top panel component 24 and the bottom panel 28. In embodiments, the mattress cover may remain unzipped.

(20) Referring to FIG. 8, in embodiments, a pillow top mattress cover may be manufactured as illustrated. A half cap unit 120 with a first pocket 122 and a flap 124 with a second pocket 126 may be assembled by a conventional sewing machine. The bottom exterior thin fabric panel 28 with a zipper is joined to the quilted sidewall border component 26. The half cap unit 120 is flipped over and placed on a dummy core 100 with the first pocket containing the dummy core 100. The assembly is again flipped over such that the dummy core 100 is exposed facing upward. A layer of foam 130, such as an eggshell panel is place in the first pocket on the dummy core. Adhesive 133 may be sprayed on by a nozzle 134. The flap is closed and a flap zipper 137 is closed. Adhesive 133 may then be reapplied and a foam layer 140 is place in the second pocket 126 and is secured to the flap, again with adhesive. The flap may be formed of the same thin fabric as the bottom exterior thin fabric panel, for example woven polyester. A quilted top panel component 24 is secured to the foam layer 140 with adhesive. A edge tape machine secures the quilted top panel component 24 to the assembly. The assembly is flipped over, the zipper 30 opened, the flap 110 moved out of the way, and the dummy core 100 is removed. The assembled mattress cover 21 may be folded and stacked in a stack 148 on a pallet 149 for shipment to a mattress assembly facility. In embodiments, the mattress covers may be shrink wrapped or vacuum packed or simply shipped in plastic bags. In embodiments, the mattress coverings may be in compilations other than flat stacks on pallets. For example they may be folded up or rolled up and be put in boxes without vertical stacks.

(21) Referring to FIG. 9, the sequence of steps of assembling a mattress at a mattress assembly facility is illustrated. Pallets 149 with stacks 148 of mattress covers 21 provide inventory for the facility as well as pallets 161 of mattress cores 22. A suitable selection of a mattress cover and core are made and the mattress cover is simply opened by way of the zipper 30, the core is installed, and the zipper is closed. In instances, an addition layer of material such as foam or non-woven felt may be installed as well. The completed mattress 20 is ready for shipment or sale.

(22) Referring to FIG. 10, methods of manufacturing, distributing, and selling mattresses are depicted. A mattress cover manufacturing facility 200 with operations such as described above ship out quantities of mattress covers. The facility may be in Asia in proximity to textile mills and labor. Containers 210 of the mattress covers may be shipped overseas to regional mattress assembly facilities 220. Such a facility will receive mattress cores from a different source, such as a mattress core manufacturing facility 226. The mattresses are assembled as described in the text associated with FIG. 9 and shipped to a distribution facility 230 where select mattresses are shipped to retail stores for direct sales to customers.

(23) Referring to FIG. 11, another embodiment of methods of manufacturing, distributing, and selling mattresses are depicted. Here the mattress assembly facility is a distribution facility 240 and operates as a direct distributor of assembled mattresses 20 to retail customers.

(24) Referring to FIG. 12, another embodiment of methods of manufacturing, distributing, and selling mattresses are depicted. Here a distribution facility 250 distributes the mattress covers 21 to retail stores 260. Mattress cores may be provided to the retail stores from the distribution facility 250 or from other sources. The retail store then sells mattresses direct to customers and assembles the mattresses at the retail store. This may provide many selection options to the customer and does not have the equipment, labor, and material stocking issues of current retail mattress factories.

(25) The following United States patents are hereby incorporated by reference herein for all purposes: U.S. Pat. Nos. 6,954,957; 7,089,618; 9,706,851; and 7,426,767. Published U.S. Patent Application US2013/0174350; US2007/0204566; US2008/0245690; US2014/0298589; US2015/0313373; US2016/0262549; and Us2002/0148047 are hereby incorporated by reference herein for all purposes. The above references to U.S. patents in all sections of this application are herein incorporated by references in their entirety for all purposes. Components illustrated in such patents may be utilized with embodiments herein. Incorporation by reference is discussed, for example, in MPEP section 2163.07 (B).

(26) The above references in all sections of this application are herein incorporated by references in their entirety for all purposes. All of the features disclosed in this specification (including the references incorporated by reference, including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.

(27) Each feature disclosed in this specification (including references incorporated by reference, any accompanying claims, abstract and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.

(28) The invention is not restricted to the details of the foregoing embodiment(s). The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any incorporated by reference references, any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed. The above references in all sections of this application are herein incorporated by references in their entirety for all purposes.

(29) Although specific examples have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement calculated to achieve the same purpose could be substituted for the specific examples shown. This application is intended to cover adaptations or variations of the present subject matter. Therefore, it is intended that the invention be defined by the attached claims and their legal equivalents, as well as the following illustrative aspects. The above described aspects embodiments of the invention are merely descriptive of its principles and are not to be considered limiting. Further modifications of the invention herein disclosed will occur to those skilled in the respective arts and all such modifications are deemed to be within the scope of the invention.