GB2120543A - Improvements in or relating to mattresses - Google Patents

Abstract

A mattress is produced by affixing the insulator over a major face of a spring unit by fastening means (e.g. staples) which fix the insulator to the springs, and adhesively bonding the lid or cover (which may be quilted) to the insulator.

Description

SPECIFICATION Improvements in or relating to mattresses This invention relates to mattresses.

Traditionally mattresses have been produced by firstly fixing an insulator over a major face of a wire spring unit (e.g. an assembly of coil springs), this fixing being effected by staples or other fastening means fixing the peripheral edges of the insulator to the springs. The insulator may comprise a penetration resistant layer juxtaposed against the spring unit and a fibrous batting.

Subsequently, the "lid" of the mattress (which may be comprised of the tick and fillings) must be fixed in position such that it will not move relative to the insulator. This is generally achieved by sewing a strip of material (referred to as the "fly strip") around the edges of the lid, laying the lid across the insulator, and stapling or "hog-ringing" the fly strip to each of the individual springs.

The procedure of fixing the insulator and lid may be repeated for the other major face of the spring unit. Finally a strip of fabric is provided around the peripheral edge of the spring unit to complete the mattress.

The abovedescribed method has the disadvantage that the sewing of the fly strip to the lid and the second stapling operation represent time consuming operations which limit the production rate of the mattress and increase expense.

It is an object of the invention to obviate or mitigate the abovementioned disadvantages.

According to the present invention there is provided a method of producing a mattress comprising affixing a first layer of material over a major face of a wire spring unit by fastening means which fix the first layer to the springs, and adhesively bonding a second layer to said first layer.

The use of adhesive bonding obviates the need for a fly strip and the hog-ringing of the strip to the springs. It is thus possible, using the method of the invention, substantially to increase the rate at which the mattresses may be produced.

Preferably the first layer is an insulator layer which comprises a fibrous batting, the various structures for which are well known in this field.

The fibrous batting will for preference be affixed (e.g. by needling or adhesive bonding) to a penetration resistant layer (e.g. hessian or woven polypropylene) which will be juxtaposed to the spring unit. The insulator may be fixed in position by stapling its peripheral edges to the spring units, or by any other suitable fastening means.

The lid for the mattress will preferably be comprised of the tick and fillings (such a lid being conventional in this field) may now be bonded to the batting by any suitable conventional adhesive.

The lid may of course be suitably quilted.

The other major face of the spring unit may be provided with an insulator and lid in an exactly equivalent manner, and the mattress may be completed by providing a fabric strip around the still exposed peripheral edges of the spring unit (e.g. by sewing).

It will be appreciated that the use of adhesive to bond the lid to the insulator is a quick and inexpensive way of fixing the lid such that it will not move relative to the insulator.

1. A method of producing a mattress comprising affixing a first layer of material over a major face of a wire spring unit by fastening means which fix the first layer to the springs and adhesively bonding a second layer to said first layer.

2. A method as claimed in claim 1 , wherein the first layer is affixed to the spring unit by stapling the peripheral edges of the first layer to the spring unit.

3. A method as claimed in claim 1 or 2, wherein the first layer is an insulator comprising a fibrous batting.

4. A method as claimed in claim 3 wherein the fibrous batting is affixed to a penetration resistant layer which is juxtaposed to the spring unit.

5. A method as claimed in any one of claims 1 to 4 wherein the second layer is comprised of the tick and fillings.

6. A method as claimed in any one of claims 1 to 5 wherein the second layer is quilted.

7. A method as claimed in any one of claims 1 to 6 further comprising affixing to the other major face of the spring unit a further first layer of material by fastening means which fix said further first layer to the springs, adhesively bonding a further second layer to said further first layer and providing a fabric strip around the exposed peripheral edge of the spring unit.

8. A method of producing a mattress substantially as hereinbefore described.

**WARNING** end of DESC field may overlap start of CLMS **.

Claims (8)

**WARNING** start of CLMS field may overlap end of DESC **. SPECIFICATION Improvements in or relating to mattresses This invention relates to mattresses. Traditionally mattresses have been produced by firstly fixing an insulator over a major face of a wire spring unit (e.g. an assembly of coil springs), this fixing being effected by staples or other fastening means fixing the peripheral edges of the insulator to the springs. The insulator may comprise a penetration resistant layer juxtaposed against the spring unit and a fibrous batting. Subsequently, the "lid" of the mattress (which may be comprised of the tick and fillings) must be fixed in position such that it will not move relative to the insulator. This is generally achieved by sewing a strip of material (referred to as the "fly strip") around the edges of the lid, laying the lid across the insulator, and stapling or "hog-ringing" the fly strip to each of the individual springs. The procedure of fixing the insulator and lid may be repeated for the other major face of the spring unit. Finally a strip of fabric is provided around the peripheral edge of the spring unit to complete the mattress. The abovedescribed method has the disadvantage that the sewing of the fly strip to the lid and the second stapling operation represent time consuming operations which limit the production rate of the mattress and increase expense. It is an object of the invention to obviate or mitigate the abovementioned disadvantages. According to the present invention there is provided a method of producing a mattress comprising affixing a first layer of material over a major face of a wire spring unit by fastening means which fix the first layer to the springs, and adhesively bonding a second layer to said first layer. The use of adhesive bonding obviates the need for a fly strip and the hog-ringing of the strip to the springs. It is thus possible, using the method of the invention, substantially to increase the rate at which the mattresses may be produced. Preferably the first layer is an insulator layer which comprises a fibrous batting, the various structures for which are well known in this field. The fibrous batting will for preference be affixed (e.g. by needling or adhesive bonding) to a penetration resistant layer (e.g. hessian or woven polypropylene) which will be juxtaposed to the spring unit. The insulator may be fixed in position by stapling its peripheral edges to the spring units, or by any other suitable fastening means. The lid for the mattress will preferably be comprised of the tick and fillings (such a lid being conventional in this field) may now be bonded to the batting by any suitable conventional adhesive. The lid may of course be suitably quilted. The other major face of the spring unit may be provided with an insulator and lid in an exactly equivalent manner, and the mattress may be completed by providing a fabric strip around the still exposed peripheral edges of the spring unit (e.g. by sewing). It will be appreciated that the use of adhesive to bond the lid to the insulator is a quick and inexpensive way of fixing the lid such that it will not move relative to the insulator. CLAIMS

1. A method of producing a mattress comprising affixing a first layer of material over a major face of a wire spring unit by fastening means which fix the first layer to the springs and adhesively bonding a second layer to said first layer.

2. A method as claimed in claim 1 , wherein the first layer is affixed to the spring unit by stapling the peripheral edges of the first layer to the spring unit.

3. A method as claimed in claim 1 or 2, wherein the first layer is an insulator comprising a fibrous batting.

4. A method as claimed in claim 3 wherein the fibrous batting is affixed to a penetration resistant layer which is juxtaposed to the spring unit.

5. A method as claimed in any one of claims 1 to 4 wherein the second layer is comprised of the tick and fillings.

6. A method as claimed in any one of claims 1 to 5 wherein the second layer is quilted.

7. A method as claimed in any one of claims 1 to 6 further comprising affixing to the other major face of the spring unit a further first layer of material by fastening means which fix said further first layer to the springs, adhesively bonding a further second layer to said further first layer and providing a fabric strip around the exposed peripheral edge of the spring unit.

8. A method of producing a mattress substantially as hereinbefore described.