AU2010202955A1

AU2010202955A1 - A casing for a mattress

Info

Publication number: AU2010202955A1
Application number: AU2010202955A
Authority: AU
Inventors: Simon Cowen; Nita Indriani
Original assignee: PACIFIC BRANDS HOUSEHOLD PRODUCTS Pty Ltd
Current assignee: Australian Comfort Group Pty Ltd
Priority date: 2009-07-13
Filing date: 2010-07-13
Publication date: 2011-01-27
Also published as: AU2010246501A1

Description

Regulation 3 2 AUSTRALIA Patents Act 1990 COMPLETE SPECIFICATION STANDARD PATENT Invention Title: A casing for a mattress The following statement is a full description of this invention, including the best method of performing it known to us: 2 A CASING FOR A MATTRESS Field of the invention The present invention relates to a casing for a mattress. In particular, although not exclusively, the invention relates to a casing for an inner spring mattress where the 5 casing includes a side panel around the perimeter of the mattress and the side panel is divided into upper and lower portions by a side tape. The invention also relates to a mattress as well as a method of mattress construction. Background of the invention Mattress construction and design vary considerably to offer a range of products with 10 varying grades of user comfort and different price points. A standard mattress construction has an internal mattress assembly covered by a mattress casing. Typically, in a standard mattress, the mattress casing includes a top panel and a bottom panel with a perimetral side panel extending around all four sides of the mattress casing. The side panel is joined to the top panel by joining tape in which the raw edge 15 of the top panel and the raw upper edges of the side panel are encased between a folded strip which is sewn along its overlapping longitudinal edges. Likewise, a taped seam is formed at the lower edge of the side panel and the bottom panel. The top panel may be quilted and/or padded for increased user comfort. Variations on the standard mattress include a "Pillow Top" construction where the quilt 20 panel forming the top panel is separated from the upper edge of the side panel by a gusset panel extending therebetween. A taped seam is formed at the upper edge of the gusset panel and the top panel as well as at the lower edge of the gusset panel and the side panel. Thus, in this construction three taped seams are apparent. A "Euro" construction is similar in that it also includes a small gusset, although in this case the 25 gusset is of a different configuration than the pillow top. The end result is that three taped seams will be apparent. In a more deluxe variation, a boxed or walled pillow top is similar to a normal pillow top, except that there are additional layers of foam or padding between the gusset and the 3 top quilt panel. Therefore, in this construction between the top panel and the bottom panel, there is a side panel comprised of three portions including an upper side panel, a gusset panel and a lower side panel. In this construction, there are four taped seams. Therefore, it will be apparent that additional taped seams in a mattress (beyond the 5 standard top and bottom taped seams) indicate an increased level of user comfort. It has therefore become known to apply an additional tape to a standard mattress construction, in between the top seam and the bottom seam to give the impression of greater user comfort. This additional tape may be sewn on to the side panel. However, this arrangement has been found to be less than satisfactory because it does not have 10 the true appearance of a taped seam. The additional tape often flattens out at the corners and therefore does not stand proud of the side of the mattress as do true taped seams. Further, the additional tape does not always extend in a straight line. Reference to any prior art in the specification is not, and should not be taken as, an acknowledgment or any form of suggestion that this prior art forms part of the common 15 general knowledge in Australia or any other jurisdiction or that this prior art could reasonably be expected to be ascertained, understood and regarded as relevant by a person skilled in the art. It is therefore an object of the present invention to provide an alternative mattress casing, mattress and method of constructing a mattress which addresses at least some 20 of the abovementioned problems. An alternative object of the invention is to provide a mattress casing, mattress and method of construction which at least provides an alternative to known products. Summary of the invention In accordance with a first aspect of the present invention, there is provided a casing for 25 a mattress having an internal mattress assembly, the casing including: top and bottom panels; 4 a perimetral side panel extending between the top and bottom panels, wherein the side panel is divided into upper and lower portions by side tape applied to the side panel and extending in the lengthwise direction of the side panel; and one or more securing portions secured to the side panel, the one or more 5 securing portion for securement to the internal mattress assembly to maintain the position of the side tape relative to the internal mattress assembly. A mattress including the internal mattress assembly with the securing portion affixed thereto forms a second aspect of the present invention. In this specification the terms "right side" and "wrong side" are used in the traditional 10 garment construction sense. The "right side" is the best side of the fabric piece intended to be visible in the finished construction. "Wrong side" means the other side, not intended to be visible in the finished product. The perimetral side panel may be connected to the top and bottom panels by respective joining tapes. However, in an alternative construction, the side panel may not be joined 15 directly to either one or both of the top and bottom panels. For example, there may be an intervening gusset between the top panel and the side panel and therefore the side panel may be connected directly to the gusset panel. The side panel may be made up of a number of pieces. For example, there may be four pieces corresponding to the head, foot and the two sides of the mattress. Alternatively, 20 the side panel may be constructed of a continuous length with a single join. Furthermore, the side panel may be constructed from multiple lengths of material each extending the full perimeter of the mattress casing. For example, the side panel may be comprised of a one piece upper side panel above the side tape and a one piece lower side panel below the side tape. The side tape may be applied at the join between the 25 upper side panel and the lower side panel. The join may be obtained in any known manner, e.g. by gluing but it is most preferably sewn.

5 The side panel may be constructed of lengths of any suitable material/fabric and may be comprised of a number of layers of suitable fabrics. The side panel may be a quilted construction. The top and bottom panels may be of identical construction and therefore may not be 5 pre-designated, i.e. the mattress may be used either way up. Alternatively, there may be dedicated top and bottom panels. For example, the top panel may comprise a quilted or padded construction whereas the bottom panel may be unpadded. The side tape may comprise a strip of material in a single layer. In the sewn join, the lower longitudinal edge of the upper side panel, the upper longitudinal edge of the lower 0 side panel and one of the longitudinal edges of the tape meet and are sewn therealong so that in the finished side panel, the other edge of the side tape is exposed on the right (outer) side of the side panel. In this version, the edges of the upper and lower side panels have their right sides facing each other with the raw edges projecting to the inside of the casing. 15 Alternatively, the side tape may be a strip, preferably of fabric which is folded so that its longitudinal edges overlap. In the above described embodiment with joined upper and lower side panels, the longitudinal edges of the folded strip overlap so that the tape covers the raw longitudinal edges of the upper and lower side panels (wrong sides facing). The tape is then sewn and in the finished casing, the folded edge of the strip 20 projects from the right side of the side panel, i.e. the outside of the casing. In an alternative embodiment, the side panel may be comprised of a single width of material with the side tape applied intermediate the width, i.e. intermediate the top and bottom panels. In this embodiment, the side tape, preferably a strip of fabric is folded so that its longitudinal edges overlap and the material of the side panel is pinched 25 therebetween. The assembly is then sewn along/adjacent the overlapping edges of the strip so that the stitching extends through both edges of the strip and the two layers of side panel material are pinched therebetween. The folded edge of the side tape will project from the outside of the casing.

6 The side tape is applied intermediate the top and bottom panels. The side tape may be applied closer to the top than to the bottom. Alternatively, the side tape may be in a more central position. The side tape suitably extends the full perimeter of the mattress casing, the ends meeting at the join(s) in the side panel. 5 While the invention concerns the use of side tape, tape may also be utilised in other parts of the mattress casing. For example, tape may be utilised as joining tape to join panels of the casing such as the side panel to the bottom panel to form taped seams. As with the preferred construction of the side tape, with the joining tape, the strip of material is folded so that the longitudinal edges overlap and the raw edges of the side 10 panel and the bottom panel, are received therebetween. The assembly is then sewn along/adjacent the overlapping edges to form a taped seam. Glue may also be used to hold the edges in position prior to sewing. The strip used in the joining tape may be the same type of material as the strip used in the side tape. The side tape may include an internal cord extending along the length of the tape. This 15 renders the side tape with greater fullness or plumpness to improve its appearance. The intention is to give the side tape an appearance which resembles the joining tapes to give the impression that the thickness of mattress between the side tape and the upper joining tape is an extra padded layer, giving the impression of greater user comfort. 20 The internal cord may be comprised of twisted yarns, for example of the type used in piping cord. Alternatively, the internal cord may be plastic cord such as extruded plastic with a circular cross-section. The one or more securing portions are used to secure the mattress casing to the internal mattress assembly. In particular, the one or more securing portions ensure that 25 the side tape maintains its intended position relative to the internal mattress assembly. The one or more securing portions may comprise a number of discrete portions. For example, there may be four lengths corresponding to the four sides of the mattress. The four lengths may stop short of the corners to avoid unnecessary bulk in those 7 regions. Alternatively, the one or more securing portions may comprise a single securing portion extending at least substantially the length of the side panel. The single securing portion may have mitred or gusseted corners for a better fit with the internal mattress assembly. The securing portion may be joined to itself at the join in the side 5 panel or alternatively, may stop just short of the join to avoid unnecessary bulk. The one or more securing portions may be disposed in a number of alternative positions relative to the side panel. For example, the one or more securing portions may be attached to the mattress casing either at the top or bottom taped seams. In such an arrangement, the one or more securing portions would extend inwardly from the seams 10 to facilitate attachment to the top or bottom (as appropriate) of the internal mattress assembly. The one or more securing portions are preferably joined to the taped seams by being sewn into the taped seams. However, in a more preferred form of the invention, the one or more securing portions are joined to the mattress casing by being attached directly to the side tape 15 construction. For example, where the side panel comprises an upper panel portion and a lower panel portion, the one or more securing portions may be attached by having its outer longitudinal edge sewn into the join between the upper panel portion and the lower panel portion. Suitably, the one or more securing portions will extend inwardly from the wrong side (inside) of the side panel. 20 It is possible that the one or more securing portions may comprise a combination of securing portions disposed at any one or more of: the top taped seam; the bottom taped seam; and the side taped seam. Where the one or more securing portions are attached to the top or bottom taped seams then the free edges of the one or more securing portions may be affixed to the top or 25 bottom of the mattress as appropriate. For example, the mattress casing may be constructed by joining the side panels to the bottom panel to form a "bucket" which is slipped over the internal mattress assembly. If the securing portions are disposed at the bottom taped seams then they may be glued or otherwise secured to the base of the mattress. The top panel is then laid over the internal mattress assembly (with or without 8 additional layers of foam or padding) and glued if necessary. The top taped seam is then formed to close the mattress casing. However, a more preferred form of the invention is an arrangement with a securing portion (preferably in a single piece), extending substantially the full perimeter of the 5 side panel with one edge of the securing portion connected to the side tape construction. In this embodiment, the internal mattress assembly is comprised of a main portion and one or more upper layers of foam or padding. The main portion includes the spring unit. In this construction, the bottom panel is joined to the side panel to form a partially formed casing or bucket and the main portion of the internal mattress 10 assembly is received in the partially formed casing. The securing portion is then secured to the top of the main portion, preferably by gluing. Then the one or more upper layers of foam or padding are laid over the main portion and the securing portion. The top panel is then overlaid over the one or more upper layers. The mattress casing is then closed by forming the top seam. 15 The main portion of the internal mattress assembly may have a variety of constructions. Firstly, it may simply comprise an inner spring unit. Alternatively, the inner spring unit may be surrounded top and bottom by foam or padding such as a densified fibre. In a third version, the inner spring unit may be encased in foam top, bottom and sides. This third version is used in the more expensive models. 20 In accordance with a third aspect of the present invention, there is provided a method of mattress construction including: forming at least a portion of a mattress casing having: one or both of top and bottom panels attached to a perimetral side panel, with a side tape applied to the side panel and extending in the lengthwise direction of the side panel; and one or more 25 securing portions secured to the side panel; inserting an internal mattress assembly into the portion of the mattress casing; and 9 securing the one or more securing portions to the internal mattress assembly to maintain the desired position of the side tape. Additional steps may be included as described above in connection with the foregoing aspects of the invention. 5 In accordance with the fourth aspect of the present invention there is provided a method of forming at least a portion of a mattress casing having a perimetral side panel comprised of an upper panel portion and a lower panel portion with a side tape applied along the join therebetween, the method comprising: joining the longitudinal edges of the upper panel portion and the lower panel 10 portion with the side tape, wherein the side tape includes an internal cord extending along the tape. The side panel may be joined to a top panel and bottom panel to form the completed mattress casing as described above in the previous aspects of the invention. As used herein, except where the context requires otherwise, the term "comprise" and 15 variations of the term, such as "comprising", "comprises" and "comprised", are not intended to exclude further additives, components, integers or steps. Brief description of the drawings / figures The invention will now be described, by way of example only, with reference to the accompanying drawings, in which: 20 Figure 1 is a perspective view and exploded view of the side portion of a mattress casing according to a preferred embodiment of the present invention; Figure 2 is a cross sectional view of a taped seam of the side portion of the mattress casing shown in Figure 1; 10 Figure 3 is a an exploded perspective view of a mattress according to a preferred embodiment of the present invention, incorporating the side portion of the mattress casing shown in figure 1, top and bottom panels of the mattress casing and an internal mattress assembly; 5 Figure 4 is a perspective view of the completed mattress of Figure 3; Figure 5a is a partial cross sectional view of the lower portion of the mattress shown in Figure 3, showing a first form of a main portion of an internal mattress assembly within the mattress; and Figure 5b is a partial cross sectional view of a mattress showing an alternative form of 10 the main portion of an internal mattress assembly within the mattress. Detailed description of the embodiments The construction of the side portion 10 of a mattress casing is illustrated in Figure 1. Side portion 10 includes a perimetral side panel 17 and securing portion 13. The perimetral side panel 17 is preferably comprised of an upper side panel 11 and a lower 15 side panel 12. The lower side panel 12, the upper side panel 11 and the securing portion 13 are initially cut to width and have their longitudinal edges finished. This may be achieved simultaneously by passing a continuous length of material from a roll through a serger (otherwise known as a double overlocker) to finish both edges and cut to the required 20 width at the same time. The lower side panel 12 and securing portion 13 are then sewn together as indicated by diagrammatic stitch 29 (Figure 2). The stitch 29 joins the wrong side 18 of top edge 25 of the lower side panel 12 to the spring side 33 of outer edge 14 of the securing portion 13. Continuous lengths of material defining lower side panels 12 and securing portions 25 13 may be joined and then cut to individual lengths for each mattress casing.

11 The upper side panel 11 and lower side panel 12, including attached securing portion 13, are joined at a taped seam 22. The wrong side 18a of bottom edge 24 of the upper side panel 11 is aligned and facing the fill side 32 of the outer edge 14 of securing portion 13. Side tape 16 extends along the length of taped seam 22. Preferably, side 5 tape 16 is folded along its longitudinal axis such that the longitudinal side tape edges 23 overlap and cover the right side 19a of the bottom edge 24 of upper side panel 11 and the right side 19 of the top edge 25 of lower side panel 12. The tape is affixed by thread 20 sewn between longitudinal tape edges 23 and through edges 14, 24, 25 caught therebetween. Along and within the fold of the tape 16 is incorporated an internal cord 10 21, such as piping cord. Each side panel 11, 12 and securing portion 13 preferably comprises a single length of fabric spanning the perimetral mattress casing 10. Referring again to Figure 1, the starting ends 34 of the side panels 11, 12 are sewn to the finishing ends 35 to configure the perimetral mattress casing as a sleeve. The starting edge 34 and finishing edge 35 15 are sewn together with their right sides in contact with each other, such that the raw edges 34, 35 of the side panels extend inwardly of the mattress casing. As shown in Figure 3, the lowermost edge 47 of side portion 10 of the mattress casing is joined to bottom panel 44 to form a "bucket". The preferable method of attachment is by applying tape along the perimeter of the join and stitching the two longitudinal edges 20 of tape together while the edges of side portion 10 and bottom panel 44 are caught therebetween. This creates a bottom taped seam 50 (figure 4). Referring again to Figure 3, the bucket is slipped over the main portion 40 of the internal mattress assembly. The spring side 31 of securing portion 13 is secured by adhesive to the upper surface 46 of main portion 40 such that taped seam 22 is secured in a straight 25 line along the perimeter of side portion 10. At each corner of the mattress casing, the securing portion 13 is folded in gusset fashion to lie flat against the upper surface 46. Upper layers 42 of foam or other padding are then placed and secured, preferably by adhesive, above the fill side 32 of the securing portion 13 and the upper surface 46 of main portion 40 of the internal mattress assembly. The internal mattress assembly is 30 covered with quilted top panel 48. Top panel 48 is attached along its perimeter to 12 uppermost edge 49 of the side portion 10. The method of attachment is by applying tape along the perimeter of the join and stitching the two longitudinal edges of tape together while the edges of side portion 10 and top panel 48 are caught therebetween. This creates a top taped seam 52 (Figure 4) along the perimeter of mattress 80. 5 A first form of the main portion 40 of the internal mattress assembly is shown in Figure 5a. A mattress housing "box" is created by adhering four walls 60 along the perimeter of a base 62. Preferably, the base 62 is made from densified fibre and the walls 60 are made from foam. The upward side 64 of inner spring unit 66 is covered with wadding 68 consisting of a soft sheet of fabric. The wadding 68 overhangs the edges of the upper 10 side 64 of the inner spring unit 66. Overhung wadding 69 is folded to tightly wrap around the upper side perimeter 70 of the inner spring unit 66. The wadding 68 is secured to the spring unit 66 by staples, preferably hog rings. Inner spring unit 66 and its adjoined wadding 68 are located on top of base 62 of the mattress housing. The walls 60 of the mattress housing are adhered, preferably by glue, to the overhung wadding 69. 15 Consistent with figures 3 and 4, main portion 40 is located within the previously formed mattress casing "bucket". Securing portion 13 is adhered to upper surface 46. Upper layers 42 (not shown in Fig. 5a) are located on the upper surface 46 and the top panel 48 (not shown in Fig. Sa) is attached-to complete the mattress 80. An alternative form of main portion 40 is shown in Figure 5b. Inner spring unit 66 is 20 sandwiched between a base 62 and a cover 72. Preferably, the base 62 and cover 72 are each made from densified foam. Consistent with figures 3 and 4, main portion 40 is located within the previously formed mattress casing "bucket". Securing portion 13 is adhered to upper surface 46, upper layers 42 (not shown in Fig. 5b) are located thereupon, and the top panel 48 (not shown in Fig. 5b) is attached to complete the 25 mattress 80. It will be understood that the invention disclosed and defined in this specification extends to all alternative combinations of two or more of the individual features mentioned or evident from the text or drawings. All of these different combinations constitute various alternative aspects of the invention.

Claims

1. A casing for a mattress having an internal mattress assembly, the casing including: top and bottom panels; 5 a perimetral side panel extending between the top and bottom panels, wherein the side panel is divided into upper and lower portions by side tape applied to the side panel and extending in the lengthwise direction of the side panel; and one or more securing portions secured to the side panel, the one or more securing portions for securement to the internal mattress assembly to maintain the 10 position of the side tape relative to the internal mattress assembly.

2. The casing as claimed in claim 1, wherein the upper and lower portions comprise an upper side panel and a lower side panel with the side tape applied at the join between the upper side panel and the lower side panel to form a side tape construction.

3. The casing as claimed in claim 2, wherein the right side of the lower longitudinal 15 edge of the upper panel faces the right side of the upper longitudinal edge of the lower panel with one of the longitudinal edges of the side tape received therebetween so that in the finished side panel, the other edge of the side tape is exposed on the outer side of the side panel.

4. The casing as claimed in claim 2, wherein the side tape is a strip which is folded 20 so that its longitudinal edges overlap such that the tape covers the raw longitudinal edges of the upper and lower side panels.

5. The casing as claimed in claim 1, wherein the side panel is comprised of a single width of material with the side tape applied intermediate the width, the side tape being a strip of fabric folded so that its longitudinal edges overlap and the material of the side 25 panel is pinched therebetween to form a side tape construction. 14

6. The casing as claimed in any one of the preceding claims, wherein the side tape includes an internal cord extending along the length of the tape.

7. The claims as claimed in any one of the preceding claims, wherein the one or more securing portions are attached to the mattress casing at the join between the top 5 panel and the side panel and/or the join between the bottom panel and the side panel.

8. The casing as claimed in any one of claims 1 to 6, wherein the one or more securing portions are joined to the mattress casing by being attached directly to the side tape construction.

9. The casing as claimed in claim 2 or 3, wherein the one or more securing portions 0 is attached by having its outer longitudinal edge sewn into the join between the upper panel and the lower panel.

10. A mattress including the casing as claimed in any one of the preceding claims and an internal mattress assembly, with the one or more securing portions affixed to the internal mattress assembly. 5

11. The mattress as claimed in claim 10 when appended to claim 8 or 9, wherein the internal mattress assembly is comprised of a main portion and one or more upper layers of foam or padding, the one or more securing portions being secured to the top of the main portion.

12. The mattress as claimed in claim 11 wherein the one or more upper layers of 20 foam or padding are disposed over the main portion and the securing portion but underneath the top panel.

13. A method of mattress construction including: forming at least a portion of a mattress casing having: one or both of top and bottom panels attached to a perimetral side panel, with a side tape applied to the side 25 panel in a side tape construction and extending in the lengthwise direction of the side panel; and one or more securing portions secured to the side panel; 15 inserting at least a portion of an internal mattress assembly into said portion of the mattress casing; and securing the one or more securing portions to said portion of the internal mattress assembly to maintain the desired position of the side tape. 5

14. The method as claimed in claim 13 wherein the one or more securing portions is connected to the side tape construction.

15. The method as claimed in claim 13 or 14 wherein the internal mattress assembly is comprised of a main portion and one or more upper layers of foam or padding, the method further including: 10 joining the bottom panel to the side panel to form said portion of the mattress casing; inserting the main portion of the internal mattress assembly into said portion of the casing; securing the one or more securing portions to the main portion of the internal 15 mattress assembly; and laying the one or more upper layers of foam or padding over the main portion and the one or more securing portions.

16. A method of forming at least a portion of a mattress casing having a perimetral side panel comprised of an upper panel portion and a lower panel portion with a side 20 tape applied along the join therebetween, the method comprising: joining the longitudinal edges of the upper panel portion and the lower panel portion with the side tape, wherein the side tape includes an internal cord extending along the tape. 16

17. A casing for a mattress or a mattress including a casing, substantially as hereinbefore described with reference to the accompanying figures.

18. A method of mattress construction or a method of forming at least a portion of a mattress casing, substantially as hereinbefore described with reference to the 5 accompanying figures.