FR2908615A1 - Mattress, has external fireproof cover for covering portion of foam wrap, and lower foam coating attached to three side panels, which lock springs, where side panels are coupled together by fixation parts at plastic strips - Google Patents

Abstract

The mattress has an external fireproof cover for covering a portion of a polyurethrene foam wrap, which encloses a set of helical shaped springs (35). Polymer fixation parts e.g. hook, are provided for fixing the foam wrap. The fixation parts have an end terminating into transverse rods. Lower foam coating (36) is attached with three side panels (34a, 34b, 34c), which lock up the springs. The side panels are coupled together by the fixation parts at plastic strips (32c, 32d). An independent claim is also included for a method for assembling foam wrap to enclose the helical shaped springs in a pouch in the mattress.

Description

TECHNICAL FIELD The present invention relates generally to systems

  and a method for constructing mattresses. Background Spring mattresses have been in use for over 100 years. Existing spring mattresses use a variety of spring types to form their inner core. Perhaps the most common is the traditional wire spring assembly having a set of inter-connected wire coil springs. Another type of spring ensemble is what is known as the Marshall Construction which was developed in the late 1890s by Marshall Mattress of Toronto, Canada. Marshall's design uses pockets of fabric to encapsulate each spring. In this way, the coil springs can flex separately from one another. In general, the mattresses are formed with a central portion of mattress surrounded by a mattress border construction. The central portion of the mattress may comprise a series of coil springs (Marshall springs) connected together, which may be enclosed in a fabric pocket. Alternatively, the central mattress portion may comprise poly (urethane) foam or latex layers or synthetic or natural fibers, optionally in combination with springs. To provide sufficient support and to make the mattress more robust, mattress manufacturers have introduced mattresses having an inner foam-encased core that provides improved edge support. The foam edge is typically bonded to a backing layer and the set of coil springs is joined to the backing layer by a border wire and open rings. The sleeping surface of the mattress is typically covered with a quilted fabric. In the manufacture of the mattress, the set of springs is typically attached to a lower border wire and this border wire is joined to the backing layer. The foam edge is glued in place around the set of springs.

  The stitched fabric is then attached to the side panels by stitching. It should be noted that conventional high end mattress manufacturing techniques employ an adhesive to secure together the mattress components (and, in particular, the foam wrap components) prior to sewing the outer layer of stitched cotton material. around the rest of the mattress. Specifically, one or both of the contact surfaces 2908615 2 of adjacent foam wrap components receive an adhesive spray. As the adhesive is sprayed onto one or both of the contact surfaces of the adjacent layers, the components are first aligned and then pulled into contact with each other.

The components for foam wraps, which are traditionally bonded together, have the following disadvantages. The use of adhesives to secure the foam wrap components of a mattress together results in a significant level of waste. Specifically, if the material components are set in misalignment, there is no way to separate them and attempt to reattach the foam wrap components. As a result, foam wrap components that are misaligned are often discarded as waste, thereby increasing manufacturing costs, which is highly undesirable.

As a second disadvantage, the use of adhesives to secure the foam wrap components of a mattress together can create an unpleasant amount of smoke and dirt, which is undesirable. As a third disadvantage, the use of adhesives to secure the foam wrap components of a mattress often creates audible cracking sounds as the adhesives age, which is highly undesirable. While traditional mattresses and manufacturing processes work well, there is a need in the art for improved techniques for making mattresses that are easier to manufacture by allowing efficient assembly of the foam wrap components before the mattress is sewn closed. SUMMARY OF THE INVENTION The system and methods described herein address the deficiencies of the prior art by providing a method of manufacturing a mattress which comprises the steps of providing a mattress core, providing a plurality of components of Foam wrap and secure the plurality of foam wrapping components together by inserting tab fasteners through or into the foam wrapping components. In various implementations, the foam wrap components include side panels, and optionally include an upper or lower upholstery fabric foam cover. In one aspect, the mattress comprises a foam wrap comprising foam side panels that are secured to each other using tab fasteners. In some embodiments, the foam wrap has an upper or lower foam liner that is attached to the side panel with the tab fasteners.

In another aspect, a mattress comprises a mattress core, at least one side panel joined to the mattress core by one or more tab fasteners that have sufficient mechanical strength to maintain a relative position between the mattress core and the mattress core. the side panel. In some configurations, the plastic tab fasteners secure a plurality of side panels together to form a frame around the mattress core. Embodiments of the invention may include, among other things, upper or lower foam coatings which serve to coat the mattress core. The mattress may comprise a layer of upholstery fabric defining a coating surface and applied to the upper foam liner. The upholstery layer may be permanently attached to the at least one side panel by a mechanical fastener. According to a feature of the invention, plastic tab fasteners may be used to secure a flange material associated with the finished upper and lower panels to the foam coated unit. In some embodiments, the plastic tab fastener may be, but not necessarily, in the form of a conventional heavy-duty plastic tab fastener as is known in the art. The plastic tab fastener may include an 8 cm plastic member that includes a first end shaped to define a cross bar. The plastic tongue fastener may further include a second, similarly shaped end to define a cross bar.

In some embodiments, the plastic tab fastener may be mass-produced in a unitary form commonly known as a fastener supply. The fastener stock is constructed of a loader type assembly in which individual plastic tab fasteners are arranged in a side-by-side orientation, the respective crossbars being parallel to one another. Optionally, the plastic tab fasteners are disposed with the foam wrapping elements by a conventional plastic tab fastener dispenser. For example, a plastic tab fastener dispenser can be used to attach: (1) a flange material associated with upper and lower finished panels to the foam-coated unit, ( 2) upholstery foams superior to pocket coil springs and foam side panels, (3) lower upholstery foam and pocket coil sets and foam side panels, (3) 4) foam or other side panels to coat a mattress core unit, and (5) side panels to other side panels in the corners of a mattress.

The mattress core may be an open coil spring mattress core, a mattress core with fabric coated springs, or springs disposed in a foam mattress core. Alternatively, the mattress core may be one or more resilient foam blocks that may have different firmness.

The present invention also relates to a mattress comprising: - a set of springs; a foam wrap for enclosing the set of springs having: a plurality of foam wrapping elements; one or more fasteners securing the plurality of foam wraps together, the fasteners having at least one end terminating at a substantially perpendicular end; and an outer covering covering at least a portion of the foam wrap. Advantageously, the plurality of foam wrapping elements comprises foam side panels.

Preferably, one or more of the foam wrapping elements comprise a substantially planar piece of foam. Advantageously, the side panels abut against each other to form an interface. Preferably, the foam side panels are mitered.

Advantageously, the foamed side panels are composed, at least in part, of polyurethane foam. Preferably, the fasteners comprise a polymer. Advantageously, the fasteners are fasteners with a plastic tongue.

Preferably, the plastic tab fasteners have ends terminating in a direction substantially perpendicular to the main body of the plastic tab fastener. Advantageously, the fasteners are fasteners 20 with a T-end. Preferably, the substantially flat piece of foam is in the form of a sheet. Advantageously, one or more of the foam wrapping elements is a side panel.

Preferably, one or more side panels form, at least in part, a perimeter. Advantageously, the substantially flat piece of foam is substantially the size of the outer perimeter and is disposed adjacent to the perimeter.

Preferably, a second substantially planar piece of foam, being substantially the size of the outer perimeter and being disposed adjacent and opposite the foam wrapper relative to the substantially planar piece of foam. Advantageously, the set of springs is a configuration of open coil springs, or a configuration of Marshall springs. Preferably, the outer cover is substantially flame retardant.

The present invention further relates to a method for assembling a foam wrap for enclosing pocket coil springs contained in a mattress comprising the steps of: providing a fixation tool having a needle for insertion and arranging the fasteners through a foam or fabric, the fasteners having at least one end terminating at a substantially perpendicular end; providing a first and a second foam wrapping element; and - assembling the first and second foam wrapping elements by: inserting the needle into the first foam wrapping member; Continuing to insert the needle into the second foam wrapping element; and * actuating the fastener tool to arrange the fastener at a predetermined location. Advantageously, the first and second foam wrapping elements 20 are side panels. Preferably, the side panels are mitered to form a corner assembly. Advantageously, the needle is inserted through the miter faces of the side panels at the corner assembly.

Preferably, the first foam wrapping member is a lower foam base. Advantageously, the attachment tool is inserted through the lower foam base and partially through the second foam wrapping element.

Preferably, the second foam wrapping member is a side panel. Advantageously, the fasteners comprise a polymer. Preferably, the fasteners are plastic tab fasteners having longitudinal axes.

Advantageously, the plastic tab fasteners have two ends and at least one of the two ends terminating substantially perpendicular to the longitudinal axis of the plastic tab fastener.

Preferably, the fasteners are T-end fasteners. This technique can eliminate the need for hot melt spraying adhesives, water and solvent spray adhesives, and acrylic adhesive films that are hazardous to the environment. security for the 10 operators. This technique further reduces the need for mechanical fasteners, hook and loop fasteners, and any other technique requiring additional hardware or additional assembly time in the mat manufacturing process. The mattresses described herein are less expensive to manufacture while providing more consistency in manufacturing processing. Additional features and advantages will become apparent from the following description of preferred embodiments from the claims.

BRIEF DESCRIPTION OF THE DRAWINGS These and other features and advantages of the invention will be more fully understood by the following illustrative description with reference to the accompanying drawings, in which like elements are numbered with identical reference designations and which may not be At scale. Fig. 1 is an illustration of the coil spring set in a pocket framed by foam side panels according to an illustrated embodiment of the invention; Fig. 2 is a three-quarter view of an angle assembly being secured with plastic tab fasteners according to another illustrated embodiment of the invention; Figure 3 is a three-quarter view illustrating the attachment of a lower foam liner utilizing plastic tab fasteners and the result of Figure 2; Figure 4 is a three-quarter view illustrating the attachment of a top foam liner utilizing plastic tab fasteners and the result of Figure 2; Figure 5 is an upper longitudinal view of an upper foam liner which is secured with plastic tab fasteners according to an illustrated embodiment of the invention; Figure 6 is an upper three-quarter view showing, by way of example, the attachment of side panels of an upper cover stitched to the side panels of a set of mattresses; Fig. 7 is a bottom front perspective view of a tool for dispensing plastic tab fasteners having a loader of two fasteners loaded therein; Fig. 8 is a lower front right end perspective view of the tool shown in Fig. 7 having a loader magazine 15 loaded therein; and Fig. 9 is an enlarged front perspective view of the fastener guide assembly shown in Fig. 8. Illustrative Description As described above in summary, the invention generally relates to the mattress construction and method of manufacturing for a mattress that facilitates attachment of various mattress components before the mattress is closed by sewing. The following illustrative embodiments are described with respect to methods for securing the side panels and the upper and lower foam coating or panels using plastic tab fasteners. However, the article of manufacture and methods can be used to secure any suitable component of the foam wrap using any suitable plastic tongue fastener. A set of mattress springs typically includes an upper frame and a lower frame that are spaced slightly apart and arranged in a substantially parallel configuration. Each frame (also commonly referred to as a wire box) comprises a rigid, durable wire or rod which is formed into a substantially rectangular design, the wire defining the outer periphery of its associated frame. In addition, a set of mattress springs typically includes a plurality of uniformly spaced, uniformly spaced, metal springs or coil springs extending between the upper and lower frames. Each spring comprises a longitudinal axis which extends substantially at right angles to the upper and lower frames. As can be appreciated, the plurality of springs allows the upper frame to move, or to give, to the lower frame when a downward force is applied to the upper frame. As a result, when an individual rests on the upper frame of the set of springs, the body weight of said individual is uniformly absorbed by the plurality of springs, which is highly desirable. The collective plurality of springs, called the heart of the mattress, is surrounded by foam panels more specifically. The outer periphery of the mattress core is framed by a plurality of foam side panels. Typically, the mattress core is secured by the frame of 15 foam side panels adhered thereto. The mattress core wrap is completed by the addition of floor and ceiling foam sheets or layers that are disposed below and above, respectively, the mattress core. An upper and lower foam liner is attached to the mattress core by adhering the foam liner to the foam side panels. A foam wrap, as described herein, can be any or all of the elements of the mattress core wrap. For example, the foam wrap may include a side panel, a perimeter, or an overlay attached to one or more side panels.

To provide a comprehensive understanding of the invention, certain illustrative practices and embodiments will now be described, including a method of manufacturing a mattress that attaches a set of springs or coils to a plurality of side panels and coverings. Foam upper or lower before the mattress is closed by seaming. However, it will be understood by those skilled in the art that the systems and methods described herein can be adapted and modified and applied in other applications and that such other additions, modifications and uses will not be beyond the scope thereof. . Figure 1 illustrates an exemplary side panel frame 10 and a pocket spring set 16 (mattress core) having coil (Marshall) coil springs arranged in rows. Instead of the coil springs in the pocket, the spring set can also have an open coil core or foam core. The outer rows of the coil springs of the pocket spring set 16 line the side panel frame 10.

The side panel frame 10 comprises a plurality of foam side panels 12a to d. The foam side panels 12a-d consist, for example, of polyurethane foam having a selected ILD or other suitable material known to those skilled in the art. In an embodiment, such as that illustrated in FIG. 1, the corners of the foam side panels 12a-d are mitered to facilitate coupling. However, the interface between the foam side panels 12a-d may take any form or appropriate relationship, such as a flat stop or a sawtooth configuration. The foam side panels 12a-d are attached to each other with a plastic tab fastener 14a to d. For example, the tab interfaces of the foam side panels 12a-d are attached to each other with a plastic tab fastener 14a. Similarly, the foam side panels 12b, 12c are attached via a plastic tab fastener 14b. The miter faces of the foam side panels 12b, 12d are secured to each other with a plastic tab fastener 14c. Similarly, the foam side panels 12c, 12d are attached via a plastic tongue fastener 14d. Referring now to FIG. 2, there is shown an aerial perspective view of a side panel frame constructed in accordance with the teachings herein. More particularly, FIG. 2 illustrates the method by which the side panel frame 10, as illustrated in FIG. 1, is assembled. The side panel frame 10, at least in part, comprises foam side panels 22a, 22b. In practice, the foam side panels are assembled using a plastic tab fastener dispenser 24. The plastic tab fastener dispenser 24, which will be described in more detail later, includes a plastic tab fastener magazine 28 and an insertion tip 26. The insertion tip penetrates the foam side panels 22a, 22b and has a plastic tab fastener from the magazine feeder 28. plastic tab 2908615 11 Plastic 28. The following is a general discussion of the general descriptions of the Plastic Tab Fastener and Dispenser. It should be noted that additional layers can be inserted into foam side panels. By way of example, one or more additional layers of foam may be penetrated by the insertion tip 26 during the process of attaching the foam side panels 22a, 22b. Figure 3 illustrates an exemplary mattress assembly in which a foam liner is attached to a side panel frame, according to another embodiment of the present invention. Specifically, Fig. 3 shows a perspective view of a set of mattresses, the lower foam cover 36 being attached to three side panels 34a, 34b and 34c which enclose a set of springs 35. Those skilled in the art will appreciate that the A plurality of side panels 34a, 34b and 34c may be arranged to substantially surround the lateral sides of the spring set 35. Alternatively, the side panel surrounding the spring set 35 may be made of a single piece manufactured, for example, by an extrusion process without departing from the spirit of the present embodiment. The side panels 34a, 34b, and 34c are affixed in accordance with the method elucidated in FIG. 2. In particular, the side panels 34a, 34b, and 34c comprise mitered ends and are secured using plastic tab fasteners. . Specifically, the side panels 34a, 34b are coupled together by plastic tab fasteners 32c, 32d using a plastic tab fastener dispenser (not shown). The side panels 34b, 34c are similarly secured using plastic tab fasteners 32a, 32b. After the side panels 34a, 34b and 34c (and a fourth side panel, not shown) are secured together thereby forming a frame 30 around the periphery of the set of springs 20, the lower foam liner 36 is attached to the frame of side panels. The lower foam liner 36 is adhered to the mattress assembly using a plastic tab fastener dispenser which will be discussed in more detail below. The plastic tab fasteners 38a, 38b, 38c and 38d secure the foam of the lower liner 36 to the side panel frame. (The plastic tab insertion will be discussed in more detail below. Specifically, the plastic tab fasteners 38a, 38b attach the lower foam liner 36 by inserting plastic tab fasteners 38a, 38b into the side panel 34a. Similarly, the plastic tab fasteners 38c, 38d attach the lower foam liner 36 by inserting plastic tab fasteners 38c, 38d into the side panel 34c. Referring to Fig. 4, after the lower foam liner 36 is attached to the mattress assembly, the upper foam liner 46 is applied. FIG. 4 shows a perspective view of a set of mattresses, the upper foam covering 46 being attached to the three side panels 44a, 44b and 44c which enclose a set of springs 35. It can be appreciated that the plurality of side panels 44a, 44b and 44c may be arranged to substantially surround the lateral sides of the set of springs 35. Alternatively, the side panel surrounding the set of springs 35 may be made of a single piece made, for example, by a method of 'extrusion. The side panels 44a, 44b and 44c are fixed in accordance with the method elucidated in FIG. 2. In particular, the side panels 44a, 44b and 44c comprise mitered ends and are secured by plastic tongue fasteners. The side panels 44a, 44b are coupled together by plastic tab fasteners 42c, 42d using a plastic tab fastener dispenser (not shown). The side panels 44a, 44b and 44c are similarly secured by plastic tab fasteners 42a, 42b. After the side panels 44a, 44b and 44c (and a fourth side panel, not shown) are secured together thereby forming a side panel frame around the periphery of the spring set 20, the upper foam cover 46 is secured in the frame of side panels. The upper foam liner 46 is adhered to the mattress assembly using a plastic tab fastener dispenser which will be discussed in more detail later in the specification. The plastic wand fasteners 48a, 48b, 48c and 48d secure the upper foam liner 46 to the side panel frame. Specifically, the plastic tab fasteners 48a, 48b secure the top foam liner 46 by inserting plastic tab fasteners 48a, 48b into the side panel 44a. Similarly, the plastic tab fasteners 48c, 48d secure the upper foam liner 46 by inserting plastic tab fasteners 48c, 48d into the side panel 44c. As shown in FIG. 5, to manufacture the mattress assembly according to FIG. 3 and FIG. 4, the upper or lower foam coating can be attached to the planar face of the spring set (not shown) using the dispenser of FIG. plastic tab fastener 56.

The plastic tab fastener dispenser 56 has an insertion tip 58. In one or more embodiments, the insertion tip 58 does not penetrate fully through the foam components. In practice, it has been discovered that this method of attachment is an effective means for adhering components, especially in closed cell type materials. By way of example, as illustrated in FIG. 5, the upper or lower foam coating 52 is attached to the side panel 54 by piercing through the upper or lower foam coating 52 and penetrating into, but not through, the Side panel 54. Alternatively, the side panel frame (partially comprised by the side panel 54) surrounding the spring set may consist of a single piece made, for example, by an extrusion process. Accordingly, the upper or lower foam coating can be attached to an extruded panel frame (not shown) by drilling through the upper or lower foam coating and penetrating into, but not through, the extruded panel frame. . Figure 6 shows an embodiment of a mattress assembly 64 having side panels 68a, 68b installed on the side panels 62a, 62b to permanently install a stitched top panel. The stitched upper panel 60 is attached to the foam wrap unit, which surrounds the spring set, using plastic fasteners. Specifically, the side panel 68a of the quilted top panel 60 is pulled down and is attached to the side panel 62a by piercing through the side panel 68a and penetrating, but not through, the side panel 62a. The side panel 68b of the upper piqué panel 60 is similarly pulled down and attached to the side panel 62b by piercing through the side panel 68b and penetrating, but not through, the side panel 62b. Referring now to FIGS. 7 and 8, various views of an embodiment of a tool for use in dispensing one or more plastic fasteners are shown. As will be further described below, the tool 70 is designed primarily for use in the installation of highly resistant plastic fasteners, such as a fastener 31, through various mattress components, such as than those used to build a foam wrap.

Compressed air supplies the tool 70 to dispense the plastic fasteners. Tool 70 may be derived from an EHD T-end system, such as a heavy-duty T-end fastener dispensing tool of the type manufactured and sold by Avery Dennison Corporation of Pasadena, California.

The tool 70 includes a protective housing 75 which is constructed of a rigid and durable material. The housing 75 includes a right side housing 77 and a left side housing 79 which are secured together by screws. The housing 75 further comprises a nose 72 which is fixed on the front end of the housings 77 and 79 by screws. The nose 72 is adapted to receive an elongated, highly resistant T-shaped hollow slot needle 71. The needle 71 is made to have a length that is considerably longer than other types of hollow end slit needles. T highly resistant classic. Specifically, the needle 71 is preferably approximately 8 cm long, allowing it to penetrate through two side panels of the foam wrap unit. However, it should be understood that the tool 70 may have needles of any length. The tool 70 includes a pneumatically driven ejection mechanism. Specifically, the tool 70 has a pneumatically driven cylinder 73. The pneumatically driven cylinder 73 comprises an air chamber and a telescopically mounted push rod (not shown) which is actuated in the axial direction. In practice, the activation and deactivation of the drive cylinder 73 serves to longitudinally move a slide which advances an ejector rod through the tool 70. In particular, the ejector rod (not shown) is aligned to selectively protrude axially through the needle 71 so as to expel the crossbar 85 from a fastener 81 through the open end of the needle 71. The activation and deactivation of the barrel The drive 73 is controlled by a finger switch assembly 80. The finger switch assembly 80 allows the tool 70 to be operated by hand, which is highly desirable. The plastic tab fastener 81 is preferably in the form of a strong plastic fastener. In particular, the plastic tab fastener 81 may be in the form of a very strong H-shaped fastener of the type sold by Avery Dennison Corporation as part of the Extra Heavy Duty T-end system. Specifically, the plastic tab fastener 81 is a 3 inch plastic member which includes a first end shaped to define a crossbar 83 (also commonly referred to as a T-bar), a second similarly shaped end to define a transverse bar 85 (also commonly referred to as a T-bar) and a thin filament 87 interconnecting the crossbars 83 and 85. The plastic tab fasteners may be Mass produced in a unitary form commonly known as a fastener supply (as shown as a plastic tab fastener loader 28 in FIG. 2). The fastener stock is constructed in a loader type assembly in which the individual plastic fasteners are arranged in a side-by-side orientation, the respective crossbars 83 and 85 being parallel to each other. another, each of the transverse bars being joined to an orthogonally common slider 89 by a separable connector 87. The plastic tongue fastener loader is typically manufactured by the injection molding process. In practice, the at least one plastic tab fastener loader is disposed in a fastener guide assembly 90 which will now be described in more detail. Turning to Fig. 9, the fastener guide assembly 90 includes a fastener guide 93 and a pair of guide covers 95a and 95b that together define a partially enclosed channel 96 for receiving the slider. 89, the separable connectors 87 and the transverse members 85 of the fastener magazine. It can be appreciated that the fastener guide assembly 90 is provided with a curved construction to hold the fastener loader 81 away from the article to be secured (i.e., the mattress assembly).

In other embodiments, the systems and methods described herein may be used with two-sided mattresses as well as mattresses that are capable of being used with adjustable beds. For example, a mattress for an adjustable bed may have a foam edge that has a break or a flexible component that is disposed somewhere halfway along the two long edges of the mattress. In this way, the adjustable bed will be more able to pivot about a central axis as the flexible portion constructed in the foam edge easily allows the mattress to pivot and flex. It will be understood that any set of springs can be used with the systems and methods described herein. Thus, open coil springs, pocket coil springs, foam coil springs, and even all foam units, which may include sections of different closures, may be used with the methods described herein. The shown embodiments of the present invention are intended to be merely exemplary and those skilled in the art should be able to make many variations and modifications to this without departing from the spirit of the present invention. Any such variations and modifications are intended to be within the scope of the present invention as defined in the appended claims.

By way of example, the described invention can be used for assembled foam wraps using other types of fasteners. According to other implementations, the invention may be employed in assembly using alternative types of dispensers, other than the one explicitly described.

The order in which the steps of the present process are carried out is purely illustrative in nature. In fact, the steps can be performed in any order or in parallel, unless otherwise indicated by this description.

Claims (29)

  A mattress comprising: - a set of springs (16); a foam wrap for enclosing the set of springs having: a plurality of foam wrapping elements (12a-12d, 36, 46); one or more fasteners (81) securing the plurality of foam wraps together, the fasteners having at least one end terminating at a substantially perpendicular end (83, 85); and an outer cover (60) covering at least a portion of the foam wrap.   The mattress of claim 1, wherein the plurality of foam wrapping elements comprises foam side panels (12a-12d). 20   The mattress of claim 1, wherein one or more of the foam wrapping elements comprise a substantially planar piece of foam (36, 46).   The mattress of claim 2, wherein the side panels abut one another to form an interface.   The mattress of claim 2, wherein the foam side panels are mitered. 30   The mattress of claim 2, wherein the foam side panels are composed, at least in part, of polyurethane foam.   The mattress of claim 2, wherein the fasteners comprise a polymer. 10 15 2908615 18   The mattress of claim 7, wherein the fasteners are plastic tab fasteners (81).   9. The mattress of claim 8, wherein the plastic tab fasteners have ends terminating in a direction substantially perpendicular to the main body of the plastic tab fastener.   The mattress of claim 1, wherein the fasteners are T-end fasteners.   The mattress of claim 3, wherein the substantially flat piece of foam is in the form of a sheet. 15   The mattress of claim 1, wherein one or more of the foam wrapping elements is a side panel.   The mattress of claim 12, wherein the one or more side panels form, at least in part, a perimeter.   The mattress of claim 11, wherein the substantially planar piece of foam is substantially the size of the outer perimeter and is disposed adjacent the perimeter.   The mattress of claim 14, further comprising a second substantially planar piece of foam (46), being substantially the size of the outer perimeter and being disposed adjacent and opposite the foam wrapper relative to the substantially planar piece of foam. foam (36).   The mattress of claim 1, wherein the fasteners comprise a polymer.   The mattress of claim 1, wherein the spring set 35 is an open coil spring configuration, or a Marshall coil configuration. 20 25 30 2908615 19   The mattress of claim 1, wherein the outer cover (60) is substantially flame retardant. 5   A method of assembling a foam wrap for enclosing pocket coil springs contained in a mattress comprising the steps of: providing a fastener tool (70) having a needle (71) for inserting and disposing parts fastening through a foam or fabric, the fasteners having at least one end terminating at a substantially perpendicular end; providing a first and a second foam wrapping element; and - assembling the first and second wrapping elements * inserting the needle into the first foam wrapping member; * continuing to insert the needle into the second foam wrap element; and * actuating the fastener tool to arrange the fastener at a predetermined location.   The method of claim 19, wherein the first and second foam wrapping elements are side panels.   The method of claim 20, wherein the side panels are mitered to form a corner assembly.   22. The method of claim 21, wherein the needle (71) is inserted through the miter faces of the side panels at the corner assembly.   The method of claim 19, wherein the first foam wrapping member is a lower foam base. 2908615 20   The method of claim 23, wherein the attachment tool is inserted through the lower foam base and partially through the second foam wrapping member. 5   25. The method of claim 24, wherein the second foam wrapping member is a side panel.   The method of claim 19, wherein the fasteners comprise a polymer.   The method of claim 26, wherein the fasteners are plastic tab fasteners having longitudinal axes.   The method of claim 27, wherein the plastic tab fasteners have two ends and at least one of the two ends terminating substantially perpendicular to the longitudinal axis of the tongue tab fastener. plastic material.   The method of claim 19, wherein the fasteners are T-end fasteners.