US20180279795A1

US20180279795A1 - Mattress assemblies having nested, zipperless mattress ticking assemblies

Info

Publication number: US20180279795A1
Application number: US15/934,326
Authority: US
Inventors: Harrison R. Murphy; II Juraj Michal Daniel Slavik
Original assignee: Kickball Concepts LLC
Current assignee: Kickball Concepts LLC
Priority date: 2017-03-30
Filing date: 2018-03-23
Publication date: 2018-10-04

Abstract

Mattress assemblies include a mattress core assembly and a nested, zipperless mattress ticking assembly for covering the mattress core assembly and a nested, zipperless mattress ticking assembly for covering the mattress core assembly. The nested, zipperless mattress ticking assembly includes an upper mattress ticking assembly having a top side extending over a top side of the mattress core assembly and a peripheral portion extending over a portion of the peripherally-extending side of the mattress core assembly, and a lower mattress ticking assembly having a bottom side extending over the bottom side of the mattress core assembly and a peripheral portion extending over a portion of the peripherally-extending side of the mattress core assembly. The peripheral portions of the upper and lower mattress ticking assemblies overlap each other along the peripherally-extending side of the mattress core assembly. The mattress assembly meets the flammability standards of the 16 CFR 1633.

Description

CLAIM TO PRIORITY

This application claims the benefit of U.S. Provisional Patent Application No. 62/479,098, filed Mar. 30, 2017, entitled “Mattress Assemblies Having Nested, Zipperless Mattress Ticking Assemblies”, the entire contents of which is hereby incorporated herein by reference.

FIELD OF THE DISCLOSURE

The present disclosure relates generally to mattresses, and more particularly to nested, zipperless mattress ticking assemblies, and mattresses employing the same.

BACKGROUND

According to the International Sleep Products Association (“ISPA”) 2015 Industry Report, the entire subject matter of which is incorporated herein by reference, U.S. mattress producers shipped nearly 39 million units (mattresses and foundations) in 2015, an increase of 4.5% over 2014 and the sixth consecutive yearly unit increase since 2010. Average unit prices increased by 2.2% in 2015.
Mattresses and foundations are typically sold as sets. However, more mattresses are sold annually than foundations. Some mattresses are sold as replacements for existing mattresses (without a new foundation) or are for use in platform beds or other beds that do not require a foundation. ISPA estimated that the total number of U.S. conventional mattress shipments was 20.9 million in 2014, and 22.1 million in 2015. These estimates do not include futons, crib mattresses, juvenile mattresses sleep sofa inserts, or hybrid water mattresses. These “non-conventional” sleep surfaces are estimated to comprise about 10 percent of total annual shipments of all sleep products. The value of conventional mattress and foundation shipments in 2015, according to ISPA, was $6.72 and $1.31 billion respectively, compared to $6.24 and $1.28 billion respectively in 2014.
The expected useful life of mattresses can vary substantially, with more expensive models generally experiencing the longest useful lives. Industry sources recommend replacement of mattresses after 10 to 12 years.
The ISPA also provides data on the customary sizes of mattresses and the annual sales attributable to each size of mattress. The typical sizes and sales are as follows as show in Table 1:

TABLE 1

Mattress		2014 % of	2015 % of
Size	Dimensions	Total	Total

Twin	38″ × 74.5″	20.2%	19.0%
Twin XL	38″ × 79.5″	2.1%	2.4%
Full	53″ × 74.5″	16.2%	15.4%
Full XL	53″ × 79.5″	0.7%	0.6%
Queen	60″ × 79.5″	40.1%	40.2%
King	76″ × 79.5″	15.2%	16.7%
Cal King	72″ × 84″	1.8%	1.7%
Odd Sizes	Varies	3.7%	4.0%

Mattresses are generally classified into two general types by the International Sleep Products Association (ISPA): Innerspring and Non-Innerspring. The ticking assemblies of innerspring mattresses are generally permanently closed with sewn seams and according to ISPA this segment of the industry accounts for more than 85% of unit sales and 73% of dollar sales in 2015. These designs preclude entirely the end-consumers ability to adjust or even replace inner material components of the mattress in the event of material failures, wear or desire to alter the comfort and feel of the mattress.
Only 15% of mattress unit sales and 27% of mattress dollar sales are classified by ISPA as Non-Innerspring and not all of these designs provide the end-user with the ability to access the interior elements of the mattress by means of a ticking assembly that allows opening and closing of the ticking assembly through use of a zipper. These mattresses are typically compressed, sealed in plastic to hold the compression, rolled and then stuffed in packaging that permits the mattresses to be shipped by courier services such as United Parcel Service, Federal Express or DHL. The consumer is responsible for unpackaging the mattress and placing it in their desired sleeping space.

SUMMARY

Shortcomings of the prior art are overcome and additional advantages are provided through the provision, in one embodiment, of a mattress assembly which includes, for example, a mattress core assembly and a nested, zipperless mattress ticking assembly for covering the mattress core assembly and a nested, zipperless mattress ticking assembly for covering the mattress core assembly. The mattress core assembly includes top side, a bottom side, and a peripherally-extending side disposed between the top side and the bottom side. The nested, zipperless mattress ticking assembly includes an upper mattress ticking assembly and a lower mattress ticking assembly. The upper mattress ticking assembly includes a top side extending over the top side of the mattress core assembly and a peripheral portion extending over a portion of the peripherally-extending side of the mattress core assembly. The lower mattress ticking assembly includes a bottom side extending over the bottom side of the mattress core assembly and a peripheral portion extending over a portion of the peripherally-extending side of the mattress core assembly. The peripheral portions of the upper and lower mattress ticking assemblies overlap each other along the peripherally-extending side of the mattress core assembly. The mattress assembly meets the flammability standards of the 16 CFR 1633.
In another embodiment, a mattress assembly is provided. The mattress assembly includes, for example, a mattress core assembly having a top side, a bottom side, and a peripherally-extending side disposed between the top side and the bottom side, an upper mattress ticking assembly comprising a top side extending over the top side of the mattress core assembly and a peripheral portion extending over the peripherally-extending side of the mattress core assembly, and a bottom side disposed under a portion of the bottom side of the mattress core, and wherein the mattress assembly meets the flammability standards of the 16 CFR 1633.
In another embodiment, a method for forming a mattress assembly is provided. The method includes, for example, providing a mattress core assembly having a top side, a bottom side, and a peripherally-extending side disposed between the top side and the bottom side, positioning a nested, zipperless mattress ticking assembly comprising an upper mattress ticking assembly and a lower mattress ticking assembly over the mattress core assembly, and portions of the upper mattress ticking assembly and the lower mattress ticking assembly overlapping each other. The mattress assembly meets the flammability standards of the 16 CFR 1633.

BRIEF DESCRIPTION OF THE DRAWINGS

The subject matter which is regarded as the disclosure is particularly pointed out and distinctly claimed in the concluding portion of the specification. The disclosure, however, may best be understood by reference to the following detailed description of various embodiments and the accompanying drawings in which:

FIG. 1 is a perspective view of a mattress assembly and mattress foundation according to an embodiment of the present disclosure.

FIG. 2 is a cross-sectional view of the mattress assembly having a core having a single cushioning element enclosed by a nested, zipperless mattress ticking assembly taken along line 2-2 of FIG. 1 according to an embodiment of the present disclosure.

FIG. 3 is a cross-sectional view of a mattress assembly having a core having a single cushioning element enclosed by a nested, zipperless mattress ticking assembly according to an embodiment of the present disclosure.

FIG. 4 is a cross-sectional view of a mattress assembly having a core having a two cushioning elements enclosed by a nested, zipperless mattress ticking assembly according to an embodiment of the present disclosure.

FIG. 5 is a cross-sectional view of a mattress assembly having a core having a two cushioning element enclosed by a nested, zipperless mattress ticking assembly according to an embodiment of the present disclosure.

FIG. 6 is a cross-sectional view of a mattress assembly having a core having multiple cushioning elements enclosed by a nested, zipperless mattress ticking assembly according to an embodiment of the present disclosure.

FIG. 7 is a cross-sectional view of a mattress assembly having a core having multiple cushioning elements enclosed by a nested, zipperless mattress ticking assembly according to an embodiment of the present disclosure.

FIG. 8 is a cross-sectional view of a mattress assembly having a core of multiple cushioning elements enclosed by a nested, zipperless mattress ticking assembly according to an embodiment of the present disclosure.

FIG. 9 is a perspective view of a lower portion of the nested, zipperless mattress ticking assembly according to an embodiment of the present disclosure.

FIG. 10 is a perspective view of a lower portion of a nested, zipperless mattress ticking assembly according to an embodiment of the present disclosure.

FIG. 11 is a perspective view from above an upper portion of the nested, zipperless mattress ticking assembly according to an embodiment of the present disclosure.

FIG. 12 is a perspective view of an underside of an upper portion of a nested, zipperless mattress ticking assembly according to an embodiment of the present disclosure.

FIG. 13 is a perspective view of an underside of an upper portion of a nested, zipperless mattress ticking assembly according to an embodiment of the present disclosure.

FIG. 14 is a cross-sectional view from either a head or a foot of a mattress assembly having separate upper mattress core assemblies atop a single lower mattress core assembly, the core assemblies being enclosed a nested, zipperless mattress ticking assembly according to an embodiment of the present disclosure.

FIG. 15 is a cross-sectional view from either a head or a foot of a mattress assembly having a single upper mattress core assembly atop a separate lower mattress core assemblies, the core assembly being enclosed by a nested, zipperless mattress ticking assembly according to an embodiment of the present disclosure.

FIG. 16 is a cross-sectional view from either a head or a foot of a mattress assembly having separate upper mattress core assemblies atop a separate lower mattress core assemblies, the core assemblies being enclosed by a nested, zipperless mattress ticking assembly according to an embodiment of the present disclosure.

FIG. 17 is a cross-sectional view of a portion of a top side of an upper mattress ticking assembly according to an embodiment of the present disclosure extendable over a top side of a mattress core assembly.

FIG. 18 is a cross-sectional view of a portion of a top side of an upper mattress ticking assembly according to an embodiment of the present disclosure extendable over a top side of a mattress core assembly.

FIG. 19 is a cross-sectional view of a portion of a top side of an upper mattress ticking assembly according to an embodiment of the present disclosure extendable over a top side of a mattress core assembly.

FIG. 20 is a cross-sectional view of a portion of a top side of an upper mattress ticking assembly according to an embodiment of the present disclosure extendable over a top side of a mattress core assembly.

FIG. 21 is a cross-sectional view of a portion of a nested, zipperless mattress ticking assembly according to an embodiment of the present disclosure with portions of an upper mattress ticking assembly and a lower mattress ticking assembly being physically attachable or connectable via buttons or snaps.

FIG. 22 is a cross-sectional view of a portion of a nested, zipperless mattress ticking assembly according to an embodiment of the present disclosure with portions of an upper mattress ticking assembly and a lower mattress ticking assembly being physically attachable or connectable by being sewn or stitched together.

FIG. 23 is a cross-sectional view of a portion of a nested, zipperless mattress ticking assembly according to an embodiment of the present disclosure with portions of an upper mattress ticking assembly and a lower mattress ticking assembly being physically attachable or connectable via hook-and-loop fasteners.

FIG. 24 is a cross-sectional view of a mattress core assembly having a plurality of core elements and a fire barrier interliner according to an embodiment of the present disclosure.

DETAILED DESCRIPTION

The present disclosure and certain features, advantages, and details thereof, are explained more fully below with reference to the non-limiting embodiments illustrated in the accompanying drawings. Descriptions of well-known materials, fabrication tools, processing techniques, etc., are omitted so as to not unnecessarily obscure the disclosure in detail. It should be understood, however, that the detailed description and the specific examples, while indicating embodiments of the present disclosure, are given by way of illustration only, and are not by way of limitation. Various substitutions, modifications, additions and/or arrangements within the spirit and/or scope of the underlying concepts will be apparent to those skilled in the art from this disclosure. Reference is made below to the drawings, which are not drawn to scale for ease of understanding.
FIG. 1 illustrates a mattress assembly 200 supported on a mattress foundation 100 according to an embodiment of the present disclosure. As shown in FIG. 2, mattress assembly 200 may include a mattress core assembly 210 having a single core or cushioning element enclosed by a nested, zipperless mattress ticking assembly 230 in accordance with an embodiment of the present disclosure. As described and illustrated herein, the various embodiments of the nested, zipperless mattress ticking assembly provide an outermost layer of fabric, fabrics and/or related material that encloses a mattress core assembly forming a mattress assembly or mattress pad. The various embodiments described and illustrated herein of the nested, zipperless mattress ticking assembly may be formed from the various material used for forming a ticking disclosed herein. The upper and lower mattress tickings of the various embodiment of nested, zipperless mattress ticking assemblies according to the present disclosure may be releasably attachable to each other and to a mattress core assembly, partially attached to each other, or substantially attached to each other.
While description and illustration of the present disclosure is made to various embodiments of nested, zipperless ticking assemblies for mattresses, the design approaches recited herein may also be found to be beneficial in the production of articles of upholstered furniture, transportation seating or other similar cushion based articles or furnishing systems where the end-user desires to have the ability to easily access and modify, exchange or replace the internal material elements of such articles or systems and the ability to easily remove and install and even launder a removable nested, zipperless ticking assembly or exterior most fabric used in the construction of the composite article. For example, The present disclosure provides for a nested, zipperless mattress ticking assembly and a mattress made with such ticking assembly that is intended to complement and enhance the evolving designs of mattresses that are being engineered to be compressed, rolled and shipped directly to consumers, bypassing traditional retail-storefront selling settings, and that additionally are being constructed so as to provide said consumers to be able to self-modify the internal cushioning elements of the mattress.
As shown in FIG. 2, in one exemplary embodiment of the present disclosure, mattress assembly 200 may include single element mattress core assembly 210 encased by a nested, zipperless ticking assembly 230. Single element mattress core assembly 210 may include a top side 212, a bottom side 214, and a peripherally-extending side 216 disposed between top side 212 and bottom side 214.
Nested, zipperless ticking assembly 230 may include a lower or base mattress ticking assembly 240 and an upper mattress ticking assembly 260. Lower mattress ticking assembly 240 includes a bottom side 244 extending over bottom side 214 of mattress core assembly 210 and a peripheral portion 246 extending over a portion of peripherally-extending side 216 of mattress core assembly 210. Peripheral portion 246 may have a peripheral edge that is disposed generally level with top side 212 of mattress core assembly 210. Upper mattress ticking assembly 260 includes a top side 262 extending over top side 212 of mattress assembly 210 and a peripheral portion 266 extending over a portion of peripherally-extending side 216 of mattress core assembly 210. Peripheral portions 246 and 266 of upper and lower mattress ticking assemblies 240 and 260 overlap each other along peripherally-extending side 216 of mattress core assembly 210. As explained below, mattress assembly 200 meets the flammability standards of the 16 CFR 1633.
The ticking assembly is defined as being nested according to the present disclosure in that the upper mattress ticking assembly 260 overlaps the lower or base mattress ticking assembly 240 in one or more of the vertical planar faces (the mattress “border”) of the mattress construction. For purposes of the embodiment depicted in FIG. 2, the overlap is shown as being present along and across the entire height of the mattress border, however an overlap of at least 1 inch in the mattress border is contemplated by the present disclosure. The nested nature of the present disclosure also may be satisfied if the lower or base mattress ticking assembly 240 were disposed to the outside of the upper mattress ticking assembly 260.
The single element mattress assembly 210 may in its simplest form be a homogenous block of polyurethane foam. The single element mattress core assembly 210 may also be made of any variety of resilient cushioning materials customarily used in the construction of mattresses or upholstered furnishings. Such examples of foams or resilient cushioning materials can include but are not intended to be limited to latex foam; reticulated or non-reticulated visco-elastic foam (sometimes referred to as memory foam or low-resilience foam), reticulated or non-reticulated non-visco-elastic foam; gel based foams; foams infused with graphite or other substances; high-resilience polyurethane foam; expanded polymer foams (e.g., expanded ethylene vinyl acetate, polypropylene, polystyrene, or polyethylene); and the like. Such foams and resilient cushioning materials are contemplated for use for all possible embodiments disclosed herein with regards to the present disclosure.
The exemplary single element mattress core assembly 210 may be an assembled composite of a plurality of different cushioning elements that are glued, laminated or attached together to form a single unit. Utilizing different cushioning compositions or identical cushioning compositions with varied density or Indentation Force Deflection (IFD) can yield differential feel on each panel oriented face of the core assembly element. One iteration of the internal foam formulations is a laminated foam structure comprising foam slabs layered and attached to each other in the following sequence: a 1″ natural latex with an IFD of 14, 1″ of latex with an IFD of 19 or higher and a 2″ gel visco with an IFD range of 10-16.
Further referring to FIG. 2, this particular embodiment depicts the lower or base mattress ticking assembly 240 as covering the entirety of the bottom horizontal planar face (also known to those skilled in the art as the bottom panel) of the mattress core assembly and covering the four vertical planar faces (also known as the side borders) of the mattress. In this embodiment, the materials of the lower or base mattress ticking assembly 240 are not intended to transit beyond the right angle transition from the side border faces of the mattress to the top horizontal planar face of the mattress core assembly 210.
The design of the upper mattress ticking assembly 260 may be fashioned so as to have a portion 268 of the material extend into the area at bottom panel 214 of mattress core assembly 210 from at least one of the four vertical sides of the mattress assembly. The preferred embodiment would be to have the upper mattress ticking assembly 260 material extend from all four border faces to the bottom panel of the mattress, but this is not required. This feature permits the weight of the mattress and those sleeping or disposed upon the mattress to assist in holding the upper mattress ticking assembly 260 in place.
The embodiments of the present disclosure is not limited to the myriad of textiles that may be used to fashion the lower or base mattress ticking assembly 240. Suitable materials may be chosen from those known to mattress manufacturers to be sufficient to withstand the use demands and aesthetic desires of consumers.
The design approach of the exemplary embodiments recited herein uses relatively simple, single layer or fabric textile combinations and structures, however it is anticipated that more complicated, composite textile structures, such as a quilted, multi-layer assembly of decorative fabrics and thin foam sheets or fiber-based “quilting” fabric may be used in lieu of simple, single layer fabrics. Such textile structures may also include non-woven backer fabrics that assist in preparing such quilted, multi-layer assemblies and such “quilt assemblies” are well-known to the mattress manufacturing community and their use would not constitute a material departure from the present invention.
The materials for selected for use in the design of the lower or base mattress ticking assembly 240 and upper mattress ticking assembly 260 may desirably incorporate textiles with elastomeric materials that deliver stretch and recovery properties and effectively hold the interior elements together and deliver fit, finish and accessibility properties as contemplated by the present disclosure. The utilization of textiles with elastic properties is contemplated for all subsequently depicted drawings and embodiments of the present disclosure.
No zippers are used in the present disclosure to attach lower or base mattress ticking assembly 240 and upper mattress ticking assembly 260 as is customary in the production of mattresses and mattress foundation and the present embodiment is not depicted with any attachment of lower or base mattress ticking assembly 240 to the upper mattress ticking assembly 260. It is however anticipated that a ticking assembly according to the present disclosure and all embodiment depictions recited herein, may be fashioned where lower or base mattress ticking assembly 240 and upper mattress ticking assembly 260 are attached to one another by means other than a zipper, such as sewn seams, snaps, buttons or hook and loop systems.
This specific exclusion of a zipper from the design of the present disclosure is carried through all following drawings and anticipated embodiments.
The selection of material for use in these elements, as previously indicated, may be made from a wide range of choices. The operational design requirement for the material selected is that they be sufficient as judged by one skilled in the art to be used in the construction of a mattress or article of upholstered furniture.
Many of the specific detailed element descriptions provided for in FIG. 2 are also present in subsequent drawings. In the interest avoiding redundancy only those particular elements that substantially differ from or are not included in FIG. 2 will be explicitly identified in the following embodiments and corresponding drawings.
FIG. 3 illustrates a mattress assembly 300 according to an embodiment of the present disclosure that may include a single element mattress core assembly 310 encased by a nested, zipperless ticking assembly 330. Nested, zipperless ticking assembly 330 may include a lower or base mattress ticking assembly 340 and an upper mattress ticking assembly 360.
The ticking assembly is defined as being nested according to the present disclosure in that upper mattress ticking assembly 360 overlaps lower or base mattress ticking assembly 340 in one or more of the vertical planar faces (the mattress “border”) of the mattress construction. For purposes of the embodiment depicted in FIG. 3, the overlap is shown as being present along and across the entire height of the mattress border, however an overlap of at least 1 inch in the mattress border is contemplated by the disclosure. The nested nature of the present disclosure may also be satisfied if lower or base mattress ticking assembly 340 were disposed to the outside upper mattress ticking assembly 360.
The single element mattress core assembly 310 may in its simplest form be a homogenous block of polyurethane foam. The single element mattress core assembly 310 may also be made of any variety of resilient cushioning materials customarily used in the construction of mattresses or upholstered furnishings.
As with FIG. 2, the exemplary single element mattress core assembly 310 depicted in FIG. 3 may also be an assembled composite of a plurality of different cushioning elements that are glued, laminated or attached together to form a single unit. Utilizing different cushioning compositions or identical cushioning compositions with varied density or IFD can yield differential feel on each panel oriented face of the core assembly element.
Further referring to FIG. 3, the lower or base mattress ticking assembly 340 covers the entirety of the bottom horizontal planar face (also known to those skilled in the art as the bottom panel) of the mattress and covers the four vertical planar faces (also known as the side borders) of the mattress. However in this embodiment depicted in FIG. 3, the materials of lower or base mattress ticking assembly 340 may transit beyond the right angle transition from the side border faces of mattress core assembly 310 so that a portion 348 extends along a top horizontal planar face of the mattress core assembly 310 and may cover a portion of the top-most horizontal planar face adjacent the side borders or adjacent the peripherally-extending sides of mattress core assembly 310. Portion 348 may have a peripheral edge that is disposed generally inward of the peripherally-extending side and along a top side of mattress core assembly 310.
The design of upper mattress ticking assembly 360 is fashioned so as to have a portion 368 of the material extend into the area at the bottom panel from at least one of the four vertical sides of the mattress assembly. A preferred embodiment may have upper mattress ticking assembly 360 material extend from all four border faces to the bottom panel of the mattress, but this is not required. This feature permits the weight of the mattress and those sleeping or disposed upon the mattress to assist in holding upper mattress ticking assembly 360 in place.
In the embodiments shown in both FIGS. 2 and 3, the single element mattress core assembly may also incorporate a traditional mattress innerspring unit, without or without border rods, or pocketed coils or combinations thereof, and said innerspring may be cushioned only on the top and bottom horizontal planar faces of the innerspring unit or alternatively encased in foam or other flexible, resilient cushioning materials. Other internal support mechanisms customarily utilized in the production of mattresses and articles of upholstered furniture are also anticipated as being able to be encased by the nested, zipperless ticking assemblies of the present disclosure. This use of a broad variety of materials to make the core assembly is fully anticipated for all potential embodiments according to the present disclosure.
FIG. 4 depicts a mattress assembly 400 according to an embodiment of the present disclosure that may include a two-piece mattress core assembly 410 encased by a nested, zipperless ticking assembly 430. Nested, zipperless ticking assembly 430 may include a lower or base mattress ticking assembly 440 and an upper mattress ticking assembly 460. Two-piece mattress core assembly 410 may include a lower mattress core assembly 401 and an upper mattress core assembly 403 partially encased by lower or base mattress ticking assembly 440 and an upper mattress ticking assembly 460.
The ticking assembly is defined as being nested according to the present disclosure in that the upper mattress ticking assembly 460 overlaps the lower or base mattress ticking assembly 440 in one or more of the vertical planar faces (the mattress “border”) of the mattress construction. For purposes of the embodiment depicted in FIG. 4, the overlap is shown as being present in the entire height of the mattress border, however an overlap of at least 1 inch in the mattress border is contemplated by the disclosure. The nested nature of the present disclosure is also be satisfied if the lower or base ticking assembly 440 were disposed to the outside the upper mattress ticking assembly 460.
As with FIG. 1 and FIG. 2, the exemplary lower mattress core assembly 401 and upper mattress core assembly 403 depicted in FIG. 4 may also be an assembled composite of a plurality of different cushioning elements that are glued, laminated or attached together to form a single unit. Utilizing different cushioning compositions or identical cushioning compositions with varied density or IFD can yield differential feel on each panel oriented face of the core assembly element.
It is contemplated that both the lower mattress core assembly 401 and an upper mattress core assembly 403 are separate and not attached to one another and are able to rotated, flipped and interchanged individually from one another or in concert with one another, providing the end user, consumer with the flexibility to alter the cushioning attributes of the mattress by removing the ticking assembly elements and reorienting the core assembly elements. A two part core with each core possessing two distinct sides could yield eight possible orientation combinations for the mattress.
FIG. 4, similar to FIG. 1, depicts the lower or base mattress ticking assembly 440 and an upper mattress ticking assembly 460, where the lower or base mattress ticking assembly extends up the side borders only of the mattress and does not transit to the top panel face of the mattress assembly therefore not covering any portion of the upper mattress core assembly 403.
The design of the upper mattress ticking assembly 460 is fashioned so as to have a portion 468 of the material extend into the area along the bottom panel of lower mattress core assembly 401 from at least one of the four vertical sides of the mattress assembly. The preferred embodiment would be to have the upper mattress ticking assembly 460 material extend from all four border faces to the bottom panel of the mattress, but this is not required. This feature permits the weight of the mattress and those sleeping or disposed upon the mattress to assist in holding the upper mattress ticking assembly 460 in place.
FIG. 5 illustrates a mattress assembly 500 according to an embodiment of the present disclosure that may include a two-piece mattress core assembly 510 having a lower mattress core assembly 501 and an upper mattress core assembly 503 partially encased by a nested, zipperless ticking assembly 530 having a lower or base mattress ticking assembly 540 and an upper mattress ticking assembly 560.
The ticking assembly is defined as being nested according to the present disclosure in that the upper mattress ticking assembly 560 overlaps the lower or base mattress ticking assembly 540 in one or more of the vertical planar faces (the mattress “border”) of the mattress construction. For purposes of the embodiment depicted in FIG. 54, the overlap is shown as being present in the entire height of the mattress border, however an overlap of at least 1 inch in the mattress border is contemplated by the present disclosure. The nested nature of the present disclosure would also be satisfied if the lower or base mattress ticking assembly 540 were disposed to the outside the upper mattress ticking assembly 560.
Similar to FIG. 3, FIG. 5 depicts the lower or base mattress ticking assembly 540 that covers the entirety of the bottom horizontal planar face (also known to those skilled in the art as the bottom panel) of the mattress and covers the four vertical planar faces (also known as the side borders) of the mattress. However in this embodiment depicted in FIG. 5, a portion 548 of the lower or base mattress ticking assembly 540 may transit beyond the right angle transition from the side border faces of the mattress core assembly to the top horizontal planar face of the upper core assembly 503 as indicated and cover a portion of the top-most horizontal planar face of the upper mattress core assembly 510.
As with FIG. 2 and FIG. 3, the exemplary lower mattress core assembly 501 and upper mattress core assembly 503 depicted in FIG. 4 may also be an assembled composite of a plurality of different cushioning elements that are glued, laminated or attached together to form a single unit. Utilizing different cushioning compositions or identical cushioning compositions with varied density or IFD can yield differential feel on each panel oriented face of the core assembly element.
The design of the upper mattress ticking assembly 560 is fashioned so as to have a portion 568 of the material extend into the area along the bottom of lower mattress core assembly 501 from at least one of the four vertical sides of the lower mattress assembly 501. The preferred embodiment may be to have the upper mattress ticking assembly 560 material extend from all four border faces to the bottom panel of the mattress, but this is not required. This feature permits the weight of the mattress and those sleeping or disposed upon the mattress to assist in holding the upper mattress ticking assembly 560 in place.
It is contemplated that both the lower mattress core assembly 501 and an upper mattress core assembly 503 are separate and not attached to one another and are able to rotated, flipped and interchanged individually from one another or in concert with one another, providing the end user, consumer with the flexibility to alter the cushioning attributes of the mattress by removing the ticking assembly elements and reorienting the core assembly elements. A two part core with each core possessing two distinct sides could yield eight possible orientation combinations for the mattress.
In both FIGS. 4 and 5, either the lower or upper mattress core assembly or both assemblies may also incorporate an innerspring unit, said innerspring cushioned only on the top and bottom horizontal planar faces of the innerspring unit or alternatively encased in foam or other flexible, resilient cushioning materials. Other internal support mechanisms customarily utilized in the production of mattresses and articles of upholstered furniture are also anticipated as being able to be encased by the present disclosure.
FIG. 6 illustrates a mattress assembly 600 according to an embodiment of the present disclosure that may include a three-piece mattress core assembly 610 having a lower mattress core assembly 601, a middle mattress core assembly 602, and an upper mattress core assembly 603 partially encased by a nested, zipperless ticking assembly 630 having a lower or base mattress ticking assembly 640 and an upper mattress ticking assembly 660.
As with previously recited embodiments, the ticking assembly may be defined as being nested according to the present disclosure in that upper mattress ticking assembly 660 overlaps the lower or base mattress ticking assembly 640 in one or more of the vertical planar faces (the mattress “border”) of the mattress construction. For purposes of the embodiment depicted in FIG. 6, the overlap is shown as being present in the entire height of the mattress border; however an overlap of at least 1 inch in the mattress border would be contemplated by the disclosure. The nested nature of the present disclosure would also be satisfied if the lower or base mattress ticking assembly 640 were disposed to the outside the upper mattress ticking assembly 660.
The exemplary lower mattress core assembly 601, middle mattress core assembly 602 and the upper mattress core assembly 603 depicted in FIG. 6 may also be an assembled composite of a plurality of different cushioning elements that are glued, laminated or attached together to form a single unit. Utilizing different cushioning compositions or identical cushioning compositions with varied density or IFD can yield differential feel on each panel oriented face of the core assembly element.
It is contemplated that both the lower mattress core assembly 601, middle mattress core assembly 602, and upper mattress core assembly 603 are separate and not attached to one another and are able to rotated, flipped and interchanged individually from one another or in concert with one another, providing the end user, consumer with the flexibility to alter the cushioning attributes of the mattress by removing the ticking assembly elements and reorienting the core assembly elements. A three part mattress core assembly approach with each core possessing two distinct sides could yield more than thirty-two possible orientation combinations for the mattress.
FIG. 6, similar to FIG. 2 and FIG. 4, depicts lower or base mattress ticking assembly 640 and an upper mattress ticking assembly 660, where lower or base mattress ticking assembly 640 extends up the side borders only of the mattress and does not transit along a top panel face of mattress assembly 610 therefore not covering any portion of the upper mattress core assembly 603. In this FIG. 6, lower or base mattress ticking assembly 640 is not depicted as extending against the vertical border side of upper mattress core assembly 603. This embodiment is an example where an originally manufactured mattress with only two core assemblies may be enhanced by the end-user, consumer with the addition of an upper mattress core assembly 603 on an “after-market” basis atop the original two core elements 601 and 603.
The selection of material for either or both of lower or base mattress ticking assembly 640 and upper mattress ticking assembly 660 of this embodiment or of other embodiments contained herein may be made with consideration for providing sufficient structural lateral rigidity to hold unattached internal mattress core assemblies in place during shipment and consumer use.
The design of the upper mattress ticking assembly 640 is fashioned so as to have a portion 668 of the material extend into the area at the bottom from at least one of the four vertical sides of mattress assembly 610. The preferred embodiment may have upper mattress ticking assembly 660 material extend from all four border faces to the bottom panel of the mattress, but this is not required. This feature permits the weight of the mattress and those sleeping or disposed upon the mattress to assist in holding the upper mattress ticking assembly 660 in place.
FIG. 7 illustrates a mattress assembly 700 according to an embodiment of the present disclosure that may include a three-piece mattress core assembly 710 having a lower mattress core assembly 701, a middle mattress core assembly 702, and an upper mattress core assembly 703 partially encased by a nested, zipperless ticking assembly 730 having a lower or base mattress ticking assembly 740 and an upper mattress ticking assembly 760.
As with previously recited embodiments, the ticking assembly is defined as being nested according to the present disclosure in that upper mattress ticking assembly 760 overlaps lower or base mattress ticking assembly 740 in one or more of the vertical planar faces (the mattress “border”) of the mattress construction. For purposes of the embodiment depicted in FIG. 7, the overlap is shown as being present in the entire height of the mattress border; however an overlap of at least 1 inch in the mattress border is contemplated by the disclosure. The nested nature of the present disclosure may also be satisfied if lower or base mattress ticking assembly 740 were disposed to the outside upper mattress ticking assembly 760.
The exemplary lower mattress core assembly 701, middle mattress core assembly 702, and upper mattress core assembly 703 depicted in FIG. 7 may also be an assembled composite of a plurality of different cushioning elements that are glued, laminated or attached together to form a single unit. Utilizing different cushioning compositions or identical cushioning compositions with varied density or IFD can yield differential feel on each panel oriented face of the core assembly element.
It is contemplated that both lower mattress core assembly 701, middle mattress core assembly 702, and upper mattress core assembly 703 are separate and not attached to one another and are able to rotated, flipped and interchanged individually from one another or in concert with one another, providing the end user, consumer with the flexibility to alter the cushioning attributes of the mattress by removing the ticking assembly elements and reorienting the core assembly elements. A three part mattress core assembly approach with each core possessing two distinct sides could yield more than thirty-two possible orientation combinations for the mattress.
FIG. 7, similar to FIG. 3 and FIG. 5, depicts lower or base mattress ticking assembly 740 and upper mattress ticking assembly 760, where the lower or base mattress ticking assembly extends up the side borders of the mattress core assembly and a portion 748 does transit to the top panel face of the mattress assembly covering a portion of upper mattress core assembly 703.
The selection of material for either or both of lower or base mattress ticking assembly 740 and upper mattress ticking assembly 760 of this embodiment or of other embodiments contained herein may be made with consideration for providing sufficient structural lateral rigidity to hold unattached internal mattress core assemblies in place during shipment and consumer use.
The design of the upper mattress ticking assembly 760 is fashioned so as to have a portion 768 of the material extend into the area at the bottom from at least one of the four vertical sides of the mattress assembly. The preferred embodiment may have upper mattress ticking assembly 760 material extend from all four border faces to the bottom panel of the mattress, but this is not required. This feature permits the weight of the mattress and those sleeping or disposed upon the mattress to assist in holding upper mattress ticking assembly 760 in place.
FIG. 8 illustrates a mattress assembly 800 according to an embodiment of the present disclosure that may include a three-piece mattress core assembly 810 having a lower mattress core assembly 801, a middle mattress core assembly 802, and an upper mattress core assembly 803 partially encased by a nested, zipperless ticking assembly 830 having a lower or base mattress ticking assembly 840 and an upper mattress ticking assembly 860.
As with previously described embodiments, the ticking assembly is defined as being nested according to the present disclosure in that upper mattress ticking assembly 860 overlaps lower or base mattress ticking assembly 840 in one or more of the vertical planar faces (the mattress “border”) of the mattress construction. For purposes of the embodiment depicted in FIG. 8, the overlap is shown as being present in the entire height of the mattress border; however an overlap of at least 1 inch in the mattress border is contemplated by the present disclosure. The nested nature of the present disclosure would also be satisfied if lower or base mattress ticking assembly 840 were disposed to the outside upper mattress ticking assembly 860.
The exemplary lower mattress core assembly 801, middle mattress core assembly 802, and upper mattress core assembly 80 depicted in FIG. 8 may also be an assembled composite of a plurality of different cushioning elements that are glued, laminated or attached together to form a single unit. Utilizing different cushioning compositions or identical cushioning compositions with varied density or IFD can yield differential feel on each panel oriented face of the core assembly element.
It is contemplated that both lower mattress core assembly 801, middle mattress core assembly 802, and upper mattress core assembly 803 are separate and not attached to one another and are able to rotated, flipped and interchanged individually from one another or in concert with one another, providing the end user, consumer with the flexibility to alter the cushioning attributes of the mattress by removing the ticking assembly elements and reorienting the core assembly elements. A three part mattress core assembly approach with each core possessing two distinct sides could yield more than thirty-two possible orientation combinations for the mattress.
FIG. 8, similar to FIG. 3 and FIG. 5, depicts lower or base mattress ticking assembly 840 and upper mattress ticking assembly 860, where the lower or base mattress ticking assembly extends up the side borders of the mattress; however, in this FIG. 8, lower or base mattress ticking assembly 840 is not depicted as extending against the vertical border side of upper mattress core assembly 803, rather lower or base mattress ticking assembly 840 extends against the vertical border side of lower mattress core assembly 801 and middle mattress core assembly 802 only and then a portion 848 transits in partially atop an upper horizontal planar face of middle mattress core assembly 802, effectively resting and sandwiched partially between middle mattress core assembly 802 and upper mattress core assembly 803. This embodiment is an example where an originally manufactured mattress conforms to the design depicted in FIGS. 4 and 5, and the two core assemblies may be enhanced by the end-user, consumer with the addition of a third core assembly, here represented by upper mattress core assembly 803, on an “after-market” basis atop the original two core elements 801 and 802.
The selection of material for either or both of the lower or base mattress ticking assembly 840 and an upper mattress ticking assembly 860 of this embodiment or of other embodiments contained herein may be made with consideration for providing sufficient structural lateral rigidity to hold unattached internal mattress core assemblies in place during shipment and consumer use.
The design of the upper mattress ticking assembly 860 is fashioned so as to have a portion 868 of the material extend into the area along a bottom of the lower mattress core assembly 801 from at least one of the four vertical sides of the mattress assembly. The preferred embodiment would be to have the upper mattress ticking assembly 860 material extend from all four border faces to the bottom panel of the mattress, but this is not required. This feature permits the weight of the mattress and those sleeping or disposed upon the mattress to assist in holding the upper mattress ticking assembly 860 in place.
FIG. 9 is a perspective view of a lower or base mattress ticking assembly 940 according to the present disclosure for use in a nested, zipperless mattress ticking assembly or features incorporable in those previously depicted in FIGS. 2, 4, and 6, along with the core assembly elements depicted previously.
As shown in FIG. 9, lower or base mattress ticking assembly 940 is comprised of a textile that is fashioned into a shape appropriately sized to contain the mattress core elements (not shown in FIG. 9 for clarity). It is contemplated by the present disclosure that lower or base mattress ticking assembly 940 may be fashioned from one continuous piece of fabric or alternatively from a plurality of separate fabrics that sewn together, said separate fabrics may be similar or dissimilar in their compositions and their constructions.
Corners 945 of lower or base mattress ticking assembly 940 may be formed by folding the fabric or using sewn seams. Sewn seams 947 may optionally be used to assemble disparate textile elements into a comprehensive, composite structure. The locations and orientations of the seams as depicted are not intended to limiting are merely exemplary of one approach to fashion the lower or base mattress ticking assembly 940. The placement of sewn seams in all contemplated embodiments of the present disclosure may be used to facilitate the orderly placement and situation of the core assembly elements, provide structural support for and restrict lateral movement of the core assembly elements as well offer aesthetically pleasing finished appearance of the entire mattress.
Lower or base mattress ticking assembly 940 may be constructed from materials that provide appropriate structural integrity to contain the core elements without additional supporting design approaches or the textiles may be fashioned to incorporate hems or elastic bands or fabrics possessing elastic properties. For example, a portion 949 of lower or base mattress ticking assembly 940 may incorporate hems or elastic bands or fabrics possessing elastic properties. Such portion 949 may correspond to portions of the lower or base mattress ticking assemblies described above and be disposed along the vertical sides of the mattress core(s) to resiliently restrain the lower or base mattress ticking assemblies in position on the mattress core(s). Portion 949 may be a woven or knitted fabric having an elastic polyurethane material such as a LYCRA elastic polyurethane material.
FIG. 10 is a perspective view of a lower or base mattress ticking assembly 1040 according to the present disclosure for use in a nested, zipperless mattress ticking assembly or features incorporable in those previously depicted in FIGS. 3, 5, and 7, along with the core assembly elements depicted previously.
Lower or base mattress ticking assembly 1040 may include a textile that is fashioned into a shape appropriately sized to contain the core elements (not shown in FIG. 10 for clarity). It is contemplated by the present disclosure that lower or base mattress ticking assembly 1040 may be fashioned from one continuous piece of fabric or alternatively from a plurality of separate fabrics that sewn together, said separate fabrics may be similar or dissimilar in their compositions and their constructions.
The corners 1045 of lower or base mattress ticking assembly 1040 may be formed by folding the fabric or using sewn seams. Sewn seams 1047 may optionally be used to assemble disparate textile elements into a comprehensive, composite structure. The locations and orientations of the seams as depicted are not intended to limiting are merely exemplary of one approach to fashion the lower or base mattress ticking assembly 1040.
In this embodiment, lower or base mattress ticking assembly 1040 may be constructed from materials that provide appropriate structural integrity to contain the core elements without additional supporting design approaches or the textiles may be fashioned to incorporate hems or elastic bands or fabrics possessing elastic properties. For example, a portion 1041 of lower or base mattress ticking assembly 1040 may incorporate hems or elastic bands or fabrics possessing elastic properties. Such portion 1041 may correspond to portions of the lower or base mattress ticking assemblies described above and may rest atop or extend along a top horizontal side of a mattress core as described above to resiliently restrain the lower or base mattress ticking assemblies in position on the mattress core(s). Portion 1041 may be a woven or knitted fabric having an elastic polyurethane material such as a LYCRA elastic polyurethane material.
Opening 1043 in the top of lower or base mattress ticking assembly 1040 by this additional fabric structure 1041 may be sufficiently sized and configured to permit insertion of a mattress core assembly elements into the cavity provided by lower or base mattress ticking assembly 1040. The additional fabric structure may be fashioned from a single continuous piece of fabric or cloth and may also be formed by a plurality of separate and similar or dissimilar fabrics that are joined together with customary sewing techniques.
The opening created by the additional fabric structure 1041 as illustrated in FIG. 10 is rectangular, however it is anticipated that alternate designs and geometries, such as ovals, circles, diamonds or ellipses, might be fashioned and would fall within the design intent of the present disclosure.
FIG. 11 is a perspective view of an upper mattress ticking assembly 1160 according to the present disclosure for use in a nested, zipperless mattress ticking assembly or features incorporable in those previously described above, and employed with the core assembly elements previously described above.
Upper mattress ticking assembly 1160 may include a ticking fabric 1161 is fashioned to accommodate the shape of a mattress core assembly. Ticking fabric 1161 may be formed from a single continuous piece of textile material or from a plurality of separate and either similar or dissimilar textile materials. In some embodiments, ticking fabric 1161 may include a plurality of fabric layers. In some embodiments, ticking fabric 1161 may include a quilted plurality of fabric layers.
Upper mattress ticking assembly 1160 may include a second fabric 1162, which may possess desirable elastomeric properties which may be attached, preferably by sewing, to the bottom oriented edge of ticking fabric 1161. This second fabric need not be elastomeric and may be selected from a non-elastomeric material and the construction technique may use elastomeric material to add elastomeric properties to this portion of the design.
Seams may be sewn to add definition to the shape of the material and this embodiment, such as seams depicted at the vertical corners 1165 disposed over a mattress 1110 and a horizontal transition point 1167 disposed over vertical border faces of mattress 1110 to an upper horizontal planar (panel) face (not shown in FIG. 11) of mattress 1110.
FIG. 12 is a perspective view of an underside of an upper mattress ticking assembly 1260 according to the present disclosure for use in a nested, zipperless mattress ticking assembly or features incorporable in those previously described above, and employed with the core assembly elements previously described above.
In this illustrated embodiment, upper mattress ticking assembly 1260 may include a ticking fabric 1261 and a second fabric 1263 fashioned to accommodate a shape of a mattress core assembly (not shown in FIG. 12). Ticking fabric 1261 may be formed from a single continuous piece of textile material or from a plurality of separate and either similar or dissimilar textile materials.
Second fabric 1263, which may possess desirable elastomeric properties and may be attached, preferably by sewing, to the bottom oriented edge of ticking fabric 1261. This second fabric need not be elastomeric and may be selected from a non-elastomeric material and the construction technique may use elastomeric material to add elastomeric properties to this portion of the design.
Seams may be sewn to add definition to the shape of the material and this embodiment, such seams are depicted at the vertical corners of upper mattress ticking assembly 1260.
The second fabric 1263 may, in a preferred embodiment, be sufficiently sized so as to transit to some degree across the lower horizontal planar face of a mattress assembly (not shown in FIG. 12) in the area 1265 indicated by the bottom portion of the second fabric 1263. Also in this embodiment, an elastic band 1267 may be sewn into a hem of the bottom portion of the second fabric 1263. This embodiment as depicted leaves an opening 1269 sufficiently large enough to permit this upper ticking assembly to be stretched open to be installed over an assembly of a mattress core or a plurality of mattress core assembly elements that have been encased in a lower mattress ticking assembly.
FIG. 13 is a perspective view of an underside of an upper mattress ticking assembly 1360 according to the present disclosure for use in a nested, zipperless mattress ticking assembly or features incorporable in those previously described above, and employed with the core assembly elements previously described above.
In this illustrated embodiment, upper mattress ticking assembly 1360 may include ticking fabric 1361 and a second fabric 1363, and may be fashioned to accommodate a shape of a mattress core assembly (not shown in FIG. 13). For example, ticking fabric 1361 may be formed from a single continuous piece of textile material or from a plurality of separate and either similar or dissimilar textile materials.
Second fabric 1363, which may possess desirable elastomeric properties is attached, preferably by sewing, to the bottom oriented edge of ticking fabric 1361. This second fabric need not be elastomeric and may be selected from a non-elastomeric material and the construction technique may use elastomeric material to add elastomeric properties to this portion of the design.
Seams may be sewn to add definition to the shape of the material and this embodiment, such seams are depicted at the vertical corners of upper mattress ticking assembly 1360.
The second fabric 1363 may, in a preferred embodiment, sufficiently sized so as to transit to some degree across the lower horizontal planar face of a mattress assembly in an area indicated by the bottom portion of the second fabric 1363. Also in this embodiment, an elastic band 1367 may be sewn into a hem of the bottom portion of second fabric 1363. This embodiment as depicted leaves an opening 1365 sufficiently large enough to permit this upper mattress ticking assembly to be stretched open to be installed over an mattress assembly of one or a plurality of mattress core assembly elements that have been encased in a lower ticking assembly. The noted difference between this FIG. 13 and the previous FIG. 12 is the anticipation that the opening 1365 may be shaped in any shape that nonetheless permits this upper ticking assembly to be stretched open to be installed over an assembly of the plurality of mattress core assembly elements that have been encased in a lower ticking assembly.
FIG. 14 illustrates a mattress assembly 1400 taken along a head or a foot thereof according to an embodiment of the present disclosure that may include a plurality of separate upper mattress core assemblies 1411 and 1413 atop a single lower mattress core assembly 1415, said core assemblies encased by a nested, zipperless ticking assembly 1430. Nested, zipperless ticking assembly 1430 may include a lower or base mattress ticking assembly 1440 and an upper mattress ticking assembly 1460.
Lower mattress core assembly 1415 is disposed beneath first upper mattress core assembly 1411 and second upper mattress core assembly 1415.
As with previously recited embodiments, the exemplary lower mattress core assembly 11415 and first upper mattress core assembly 1411 and second upper mattress core assembly 1413 may be each, more than one or all an assembled composite of a plurality of different cushioning elements that are glued, laminated or attached together to form a single unit. Utilizing different cushioning compositions or identical cushioning compositions with varied density or IFD can yield differential feel on each panel oriented face of the core assembly element.
It is contemplated that lower mattress core assembly 1415 and first upper mattress core assembly 1411 and second upper mattress core assembly 1413 are separate and not attached to one another and are able to rotated, flipped and interchanged individually from one another or in concert with one another, providing the end user, consumer with the flexibility to alter the cushioning attributes of the mattress by removing the ticking assembly elements and reorienting the core assembly elements. A multi part core with each core possessing two distinct sides could yield at least 12 possible orientation combinations for the mattress.
This “split-top” design could permit mattress manufacturers to market their mattress as being suitable for two or more sleepers who use the mattress yet desire differential feel or comfort profiles for the side of the mattress upon which they intend to sleep. While it may be most suitable for larger sized mattress, such as queens and kings, the applicability of this design variation is anticipated for all sizes of mattress.
This “split-top” design configuration would be fully or partially encased by the present disclosure consisting of upper mattress ticking assembly 1460 and lower mattress ticking assembly 1440. This embodiment is further depicted to show the area at the bottom panel 1468 where the upper mattress ticking assembly 1460 extends below the bottom panel from at least one of the four vertical sides of the mattress assembly. The preferred embodiment would be to have the upper mattress ticking assembly 1460 material extend from all four border faces to the bottom panel of the mattress, but this is not required. This feature permits the weight of the mattress and those sleeping or disposed upon the mattress to assist in holding the upper mattress ticking assembly 1460 in place.
FIG. 15 illustrates a mattress assembly 1500 taken along a head or a foot thereof according to an embodiment of the present disclosure that may include a single upper mattress core assembly 1515 atop a plurality of separate lower mattress core assemblies 1516 and 1517, said core assemblies encased by a nested, zipperless ticking assembly 1530. Nested, zipperless ticking assembly 1530 may include a lower or base mattress ticking assembly 1540 and an upper mattress ticking assembly 1560.
First lower mattress core assembly 1516 and second lower mattress core assembly 1517 are disposed beneath upper mattress core assembly 1515.
As with previously recited embodiments, the exemplary first lower mattress core 1516 and second lower mattress core assembly 1517 that are disposed beneath upper mattress core assembly 1515 may be each, more than one or all an assembled composite of a plurality of different cushioning elements that are glued, laminated or attached together to form a single unit. Utilizing different cushioning compositions or identical cushioning compositions with varied density or IFD can yield differential feel on each panel oriented face of the core assembly element.
It is contemplated that first lower mattress core assembly 1516 and second lower mattress core assembly 1517 are disposed beneath upper mattress core assembly 1515 are separate and not attached to one another and are able to rotated, flipped and interchanged individually from one another or in concert with one another, providing the end user, consumer with the flexibility to alter the cushioning attributes of the mattress by removing the ticking assembly elements and reorienting the core assembly elements. A multi part core with each core possessing two distinct sides could yield at least 12 possible orientation combinations for the mattress.
This “split-bottom” design could permit mattress manufacturers to market their mattress as being suitable for two or more sleepers who use the mattress yet desire differential feel or comfort profiles for the side of the mattress upon which they intend to sleep. While it may be most suitable for larger sized mattress, such as queens and kings, the applicability of this design variation is anticipated for all sizes of mattress.
This “split-bottom” design configuration may be fully or partially encased by the present disclosure of upper mattress ticking assembly 1560 and the lower mattress ticking assembly 1540. This embodiment is further depicted to show the area at the bottom panel 1568 where upper mattress ticking assembly 1560 extends below the bottom panel from at least one of the four vertical sides of the mattress assembly. The preferred embodiment may have upper mattress ticking assembly 1560 material extend from all four border faces to the bottom panel of the mattress, but this is not required. This feature permits the weight of the mattress and those sleeping or disposed upon the mattress to assist in holding the upper mattress ticking assembly 1560 in place.
FIG. 16 illustrates a mattress assembly 1600 taken along a head or a foot thereof according to an embodiment of the present disclosure that may include a plurality of upper mattress core assemblies 1611 and 1613 atop a plurality of separate lower mattress core assemblies 1616 and 1617, said core assemblies encased by a nested, zipperless ticking assembly 1630. Nested, zipperless ticking assembly 1630 may include a lower or base mattress ticking assembly 1640 and an upper mattress ticking assembly 1660.
First lower mattress core assembly 1616 and second lower mattress core assembly 1617 are disposed beneath first upper mattress core assembly 1611 and second upper mattress core assembly 1613.
As with previously recited embodiments, the exemplary first lower mattress core 1616 and first upper mattress core assembly 1611, and second lower mattress core assembly 1617 and second upper mattress core assembly 1613 that may be each, more than one or all an assembled composite of a plurality of different cushioning elements that are glued, laminated or attached together to form a single unit. Utilizing different cushioning compositions or identical cushioning compositions with varied density or IFD can yield differential feel on each panel oriented face of the core assembly element.
It is contemplated that first lower mattress core assembly 1616 and second lower mattress core assembly 1617 that are disposed beneath first upper mattress core assembly 1611 and a second upper mattress core assembly 1613 are separate and not attached to one another and are able to rotated, flipped and interchanged individually from one another or in concert with one another, providing the end user, consumer with the flexibility to alter the cushioning attributes of the mattress by removing the ticking assembly elements and reorienting the core assembly elements. A multi part core with each core possessing two distinct sides could yield at least 12 possible orientation combinations for the mattress.
This “split-top and split-bottom” design could permit mattress manufacturers to market their mattress as being suitable for two or more sleepers who use the mattress yet desire differential feel or comfort profiles for the side of the mattress upon which they intend to sleep. While it may be most suitable for larger sized mattress, such as queens and kings, the applicability of this design variation is anticipated for all sizes of mattress.
This “split-top and split-bottom” design configuration would be fully or partially encased by the present disclosure of upper mattress ticking assembly 1660 and lower mattress ticking assembly 1640. This embodiment is further depicted to show the area at the bottom panel 1668 where the upper mattress ticking assembly 1660 extends below the bottom panel from at least one of the four vertical sides of the mattress assembly. The preferred embodiment would be to have upper mattress ticking assembly 1660 material extend from all four border faces to the bottom panel of the mattress, but this is not required. This feature permits the weight of the mattress and those sleeping or disposed upon the mattress to assist in holding the upper mattress ticking assembly 1600 in place.
The enhanced modularity of the design advanced in FIGS. 13, 14 and 15 may also result in logistical costs savings as the smaller pieces that are used to construct a larger mattress may be packaged separately from one another, thereby resulting in shipping costs savings as a result of the certain punitive shipping charge premiums that are typically assessed to large, oversized or non-standard parcels that may be avoided by elements of the present disclosure.
It is also fully anticipated by the present disclosure that the interiorly disposed mattress core elements that are depicted herein may be encased in knitted, tubular fire barrier socks or sleeves or that if not so covered or encased, be built into mattresses that utilize integrated fire barrier textile systems to impart into the mattress the ability to satisfy the full-scale fire test requirements of 16 CFR 1633. The absence of this feature in many of the figures herein is a result of the desire to depict the present disclosure and various embodiments of the present disclosure as clearly as is feasible.
FIG. 17 illustrates a portion of a top side 1762 of an upper mattress ticking assembly 1760 according to an embodiment of the present disclosure extendable over a top side of a mattress core assembly. In this illustrated embodiment, top side 1762 of an upper mattress ticking assembly 1760 may include a single ticking layer 1763 such as a single layer.
FIG. 18 illustrates a portion of a top side 1862 of an upper mattress ticking assembly 1860 according to an embodiment of the present disclosure extendable over a top side of a mattress core assembly. In this illustrated embodiment, top side 1862 of an upper mattress ticking assembly 1860 may include a plurality of ticking layers 1863 and 1865 each of which may be single layer, which layer are not attached together along the top side.
FIG. 19 illustrates a portion of a top side 1962 of an upper mattress ticking assembly 1960 according to an embodiment of the present disclosure extendable over a top side of a mattress core assembly. In this illustrated embodiment, top side 1962 of an upper mattress ticking assembly 1960 may include a plurality of ticking layers 1963 and 1965, each of which may be single layer or a plurality of layers, which layers may be physically attached or connected together along the top side. For example, the layers may be physically attached or connected together by sewing or stitching with thread 1961.
FIG. 20 illustrates a portion of a top side 1262 of an upper mattress ticking assembly 2060 according to an embodiment of the present disclosure extendable over a top side of a mattress core assembly. In this illustrated embodiment, top side 2062 of an upper mattress ticking assembly 2060 may include a plurality of ticking layers 2063, 2064, and 2065, each of which may be single layer or a plurality of layers, which layers may be physically attached or connected together along the top side. For example, layer 2063 may be a top fabric or quilt top layer, layer 2064 may be a batting or insulating material, and layer 2065 may be a backing material. The layers may be physically attached or connected together by sewing or stitching with thread 2061.
The upper mattress ticking assemblies disclosed in connection with FIGS. 17-20 may include any of the materials disclosed herein and may be employed in any of the disclosed mattress assembly embodiments. The bottom side of lower mattress ticking assembly may be similarly configured as described in connection with the upper mattress ticking assemblies.
FIG. 21 illustrates a portion of a nested, zipperless mattress ticking assembly 2130 according to an embodiment of the present disclosure with portions of an upper mattress ticking assembly 2160 and a lower mattress ticking assembly 2140 being physically attachable or connectable via a plurality of buttons or snaps 2170. For example, buttons or snaps 2170 may operably connect a portion 2168 of upper mattress ticking assembly 2160 that extends over a bottom side 2144 of lower mattress ticking assembly 2140. The plurality of buttons or snaps 2170 may be disposed in one or more corners, along one or more sides, along head, and/or along the foot of the mattress assembly. In other embodiments, a plurality of buttons or snaps may be disposed along a portion of the vertical sides of the nested, zipperless mattress ticking assembly. In some embodiments, the upper and lower mattress ticking assemblies may be attached along and adjacent one of the sides of the mattress assembly, which would allow removal and replacement of the nested, zipperless mattress ticking assembly.
FIG. 22 illustrates a portion of a nested, zipperless mattress ticking assembly 2230 according to an embodiment of the present disclosure with portions of an upper mattress ticking assembly 2260 and a lower mattress ticking assembly 2240 being physically attachable or connectable via being sewn or stitched together with thread 2272. For example, one or more stitches may be operably connect a portion 2268 of upper mattress ticking assembly 2260 that extends over a bottom side 2244 of lower mattress ticking assembly 2240. The one or more stitches may be disposed in one or more corners, along one or more sides, along head, and/or along the foot of the mattress assembly. In other embodiments, a stitches may be disposed a portion of the vertical sides of the nested, zipperless mattress ticking assembly. In some embodiments, the upper and lower mattress ticking assemblies may be stitched together along and adjacent one of the sides of the mattress assembly, which would allow removal and replacement of the nested, zipperless mattress ticking assembly. In other embodiments, portions an upper mattress ticking assembly and a lower mattress ticking assembly may be stitched along the entire sides of the mattress core assembly, for example where an upper mattress ticking assembly has an opening allowing receipt of a mattress core assembly.
FIG. 23 illustrates a portion of a nested, zipperless mattress ticking assembly 2330 according to an embodiment of the present disclosure with portions of an upper mattress ticking assembly 2360 and a lower mattress ticking assembly 2340 being physically attachable or connectable via one or more hook-and-loop fasteners 2373. For example, a hoop portion 2374 and a loop portion 2375 may operably connect a portion 2368 of upper mattress ticking assembly 2360 that extends over a bottom side 2344 of lower mattress ticking assembly 2340. The one or more hook-and-loop fasteners 2473 may be disposed in one or more corners, along one or more sides, along head, and/or along the foot of the mattress assembly. In other embodiments, one or more hook-and-loop fasteners may be disposed along a portion of the vertical sides of the nested, zipperless mattress ticking assembly. In some embodiments, the upper and lower mattress ticking assemblies may be attached along and adjacent one of the sides of the mattress assembly, which would allow removal and replacement of the nested, zipperless mattress ticking assembly.
From the present disclosure, it will be appreciated that the various embodiments of the mattress assemblies may include only an upper mattress ticking assembly disposed over a mattress core assembly.
The various embodiments of the mattress assembly may be configured to meet the flammability standards of the 16 CFR 1633. For example, the nested, zipperless mattress ticking assembly alone may provide flame resistant properties necessary for the mattress assembly to meet the flammability standards of the 16 CFR 1633. In other embodiments, the mattress assembly may include one or more fire barrier interliners covering said mattress core assembly to provide flame resistant properties necessary for the mattress assembly to meet the flammability standards of the 16 CFR 1633. In still other embodiments, the mattress core assembly may include one or more fire barrier interliners covering said mattress core assembly and the nested, zipperless mattress ticking assembly in combination together are operable to provide flame resistant properties necessary for the mattress assembly to meet the flammability standards of the 16 CFR 1633, i.e. neither the nested, zipperless mattress ticking assembly nor the mattress assembly along being sufficient but together the flammability standards of the 16 CFR 1633.
FIG. 24 illustrates a mattress core assembly 2400 taken along a head or a foot thereof according to an embodiment of the present disclosure that may include a plurality of layers of resilient cushioning or filling materials 2411, 2412, and 2413, said materials encased in a textile sock or sleeve 2450. FIG. 24 utilizes a scheme of changing flexible foam IFD values to promote the comfort of the end user, consumer.
In FIG. 24, the mattress core assembly 2410 includes upper layer 2411, middle layer 2412, and bottom layer 2413. All three layers in this depiction may be laminated together with adhesive material so as to constitute a singular composite piece core assembly, and this composite piece may be encased in textile sock or sleeve 2450.
The textile sock or sleeve 2450 in this preferred embodiment may include flame retardant or resistant materials customarily identified as a fire barrier interliner 2450, however the textile used may also be selected from a non-flame retardant or non-flame resistant material so as to make the mattress core assembly easier to handle during manufacture or consumer, end-user utilization. Mattress core assembly 2400 may employed as a single mattress core in a mattress assembly having a nested, zipperless mattress ticking assembly according to embodiments of the present disclosure or a plurality of mattress core assemblies 240 may be incorporated in a mattress assembly having a nested, zipperless mattress ticking assembly according to embodiments of the present disclosure. Textile sock or sleeve 2450 such as a fire barrier interliner 2450 of a plurality of fire barrier interliners may be incorporated into the various embodiments described above.
One possible iteration of the internal foam formulations depicted in this FIG. 24 is a laminated foam structure comprising foam slabs layered and attached to each other with adhesive material in the following sequence: an upper layer 1610 of 1″ natural latex with an IFD of 14, a middle layer 1620 of 1″ of latex with an IFD of 19 or higher and a bottom layer 1630 of a 2″ gel visco with an IFD range of 10-16.
Alternative ordering, such as the selection of ascending values of densities and IFDs, descending values of densities and IFDs or non-sequential ordering of densities and IFDs, is anticipated by the present disclosure.
As previously indicated, comfort is a highly subjective attribute on which the quality of mattresses may be judged by end-users, consumers. As many physical properties of a mattress or article of upholstered furniture may be altered or sequenced in particular orders to deliver different comfort properties, it is important for the mattress manufacturer to clearly and consistently orient the elements of the mattress so as to faithfully replicate the feel experienced by a consumer in the showroom. In the DTC selling model a benefit can be now be derived by mattress designs that permit consumers to reorient or resequence the interiorly disposed elements.
It is also fully anticipated by the present disclosure that the interiorly disposed mattress core elements that are depicted herein may be fully or partially encased in knitted, tubular fire barrier socks or sleeves or that if not so covered or encased, be built into mattresses that utilize integrated fire barrier textile systems or other customary fire barrier systems to impart into the mattress the ability to satisfy the full-scale fire test requirements of 16 CFR 1633. The absence of this feature in many of the FIGS. herein is a result of the desire to depict the present disclosure and various embodiments of the present disclosure as clearly as is feasible and not to indicate that a nested, zipperless mattress ticking assembly is able to satisfy regulatory driven, full-scale mattress fire testing requirements without the inclusion of a fire barrier system.

Specific Embodiments

Two embodiments (one twin sized and one queen sized) of the present disclosure was prepared in the following manner:
A lower or base mattress ticking assembly was fashioned using a 5.5 ounce per square woven cotton fabric. This material was sewn to create a five sided, flattened fabric rectangle box with bottom dimensions of 39″ wide×75″ long for twin and 60″ wide×80″ long for queen. The four sides of the box were prepared, also from the selected cotton material to extend 10″ high in the vertical direction. Seams were sewn at the corners to provide structural definition. An alternative design was also made that utilized a knitted fabric with an integrally and unitarily formed fire barrier fabric.
To the exposed top edge of the a knitted fabric comprised of nylon and lycra was sewn in accordance with the design depicted in FIG. 9 by 949
For the twin sized sample, two separate pieces of foam were covered in a knitted fire barrier fabric comprised of yarns formed from para-aramid fibers and totally chlorine free FR rayon yarns. One piece of foam was selected to serve as the lower mattress core assembly and was selected from polyurethane foam and was homogeneous in nature. This lower mattress core piece measured 38″ wide×74.5″ long by 6″ hall. The upper mattress core assembly was comprised of two separate pieces of foam, one latex and one visco elastic foam infused with gel, each measuring 38″ wide×74.5″ long×2″ high, which were glued together to form a one piece upper mattress core assembly measuring 38″ wide×74.5″ long×4″ high prior to being encased in the knitted fire barrier.
The lower mattress core assembly and the composited upper mattress core assembly were then inserted into the open cavity of the lower or base mattress ticking assembly in the appropriate order.
The assembled mattress core assemblies and lower or base mattress ticking assembly were then ready to be covered by the upper mattress ticking assembly.
The upper mattress ticking assembly was fashioned by using a knitted nylon ticking with a unitarily and integrally formed fire barrier element. This material was sewn to create a five sided, flattened fabric rectangle box with bottom dimensions of 39″ wide×75″ long for twin and 60″ wide×80″ long for queen. The height of this box was tailored to be 8″ and to the exposed edges of the box a 14″ wide band of nylon/lyrca knitted fabric with elastomeric properties was sewn. The opening that remained was then hemmed with an additional elastic band to mimic the characteristics of a fitted sheet.
The same sequences of steps and elements was followed for the queen sized unit, except the dimensions of the queen are different, as would the dimensions of the other sizes when those are constructed. Additionally, the preferred embodiments of the queen-sized and king-sized mattresses were built as depicted in FIG. 14 recited herein.
For the queen sized mattress, three separate pieces of foam were covered in a knitted fire barrier fabric comprised of yarns formed from para-aramid fibers and totally chlorine free FR rayon yarns. One piece of foam was selected to serve as the lower mattress core assembly and was selected from polyurethane foam and was homogeneous in nature. This lower mattress core piece measured 60″ wide×80″ long by 6″ high. The upper mattress core assembly was comprised of four separate pieces of foam, two latex and two visco elastic foam infused with gel, each measuring 30″ wide×80″ long×2″ high. One piece of latex was glued to one piece of visco elastic foam infused with gel to form an upper mattress core assembly measuring 30″ wide×80″ long×4″ high. The four separate pieces yield two identical upper core assembly elements and each was then encased in the knitted fire barrier.
The lower mattress core assembly and the two composited upper mattress core assemblies were then inserted into the open cavity of the lower or base mattress ticking assembly in the appropriate order.
The assembled mattress core assemblies and lower or base mattress ticking assembly were then ready to be covered by the upper mattress ticking assembly.
The upper mattress ticking assembly was fashioned by using a knitted nylon ticking with a unitarily and integrally formed fire barrier element. This material was sewn to create a five sided, flattened fabric rectangle box with dimensions of 60″ wide×80″ long for queen. The height of this box was tailored to be 8″ and to the exposed edges of the box a 14″ wide band of nylon/lycra knitted fabric with elastomeric properties was sewn. The opening that remained was then hemmed with an additional elastic band to mimic the characteristics of a fitted sheet.
The twin sized mattresses were subjected to full-scale fire testing under 16 CFR 1632.4 and 16 CFR 1633 and were observed to pass the requirements of these tests. The queen sized mattress was used for assembly trials and shipping trials as well as side-by-side comparisons of traditional, zipper-based closing processes versus the improved, faster closing process for the present disclosure and favorable results were also observed.
Throughout this description, in the interest of descriptive simplicity, only the term mattress has been used to describe the disclosure in terms of articles intended for sleeping upon. It is fully contemplated and anticipated the present disclosure is applicable to and offers benefit for the construction of mattresses and the construction of mattress foundations as defined herein. Any reference in the above specifications to the term mattress is equally intended to be applicable to the design of mattress foundations as well.
The present disclosure relates to a ticking assembly, which includes the outermost layer of fabric, fabrics and/or related material that encloses a core and upholstery materials of a mattress or mattress pad. A mattress ticking or assembly of a mattress ticking and certain cushioning elements may include several layers of fabric or related materials quilted together or it may merely be a single textile item fashioned so as to encase fully or partially the core elements of the mattress.
It is important to note that the nested, zipperless ticking assembly depicted in the present disclosure is an integral part of the mattress and is not something that is added on to a mattress by a consumer at a date subsequent to original purchase.
Federal regulations clearly define what a mattress is and that it is subject to certain testing requirements, including 16 CFR 1633—Standard for the Flammability (Open Flame) of Mattress Sets. The ticking assembly depicted herein by the present disclosure is the outermost fabric assembly of the mattress as it is manufactured for sale by the mattress manufacturer and that is subjected to this testing described above.
In accordance with the definitions found in Section 2 of the Flammable Fabrics Act as amended (15 U.S.C. 1191) and 16 CFR 1633 Standard for the Flammability (Open Flame) of Mattress Sets, it has been discovered that a consumer-removable, nested, zipperless mattress ticking assembly can deliver a variety of benefits not heretofore provided in mattress design.
It fully anticipated by the present disclosure that the textile example recited herein should not be limited to the particular fabrics described and that any materials or fabrics customarily or reasonably employed in the manufacture of mattresses or articles of upholstered furniture may be utilized to derive the benefits of the present disclosure.
Traditionally, ticking fabrics for mattresses have been yarn-based textiles that have been woven or knitted and form the outer surface of the mattresses. Woven fabrics have historically been used on innerspring mattresses, however the use of knitted fabrics as tickings has increased in concert with the increase of non-innerspring mattresses and the use of expensive, high quality cushioning materials whose comfort benefits are diminished or hidden by woven fabrics and promoted and enhanced by knits. Woven fabrics are limited in their ability to stretch and recover, whereas knitted fabrics provide stretch and recovery properties after compression to provide support that conforms to the use of resilient cushioning materials in the mattress core assembly. The complete range of woven structures is anticipated, including, but not limited to simple and compound weaves, plain weaves, oxfords, taffetas, dobby weaves, drill, twill, gabardine and the like and these fabrics may also be greige, finished, uncoated or coated. Such ticking materials may be suitably employed in the various embodiments of the present disclosure.
Because of fire performance requirements, a fire-resistant barrier material may be laminated to the inner surface of the selected ticking fabric or integrated in production to the ticking fabric. Alternatively, a fire-resistant ‘sock’ or sleeve component comprising a two-dimensional stretchable knit may be placed over the mattress core during assembly and the ticking fabric without flame resistant enhancement is placed over the knitted fire-resistant sock. Ticking fabrics may also be quilted with fibers or foams to augment their comfort and aesthetic profiles.
As is necessary now in mattress construction to ensure compliance with full-scale fire testing requirements, such as 16 CFR 1633, mattresses are protected by fire barriers or fire blocking systems. These fire barriers or fire blocking systems can take a variety of forms and in the interest of clarity and simplicity for communicating the fundamental design elements of the present disclosure, the specific nature of the fire barriers or fire blocking systems have not been explicitly shown in the drawings contained herein.
The fire barriers or fire blocking systems are most typically textile based structures. Knitted fabrics, woven fabrics, non-woven fabrics, and other similar yarn or fiber-based, inherent flame retardant or chemically treated or processed textiles and combinations thereof are the most commonly used means of delivering fire blocking performance to mattress or upholstered furniture constructions. The fire barrier or fire blocking systems can be used to independently encase the internally disposed cushioning elements of a mattress or upholstered furniture article or they may be integrated directly into the ticking textiles used to construct the outermost fabric used to construct such items. The present disclosure is contemplated to be able to accommodate all approaches presently used to deliver fire blocking performance to the design of mattresses and upholstered furniture articles.
Exemplary fibers used in the textiles formed for use as tickings or fire barriers may include organic, natural, man-made or synthetic materials, including but not necessarily limited to cotton, nylon, rayon, wool, linen, silk, acrylic, olefin, polypropylene, polyesters, bi-component polyesters and elastomeric materials.
More specific examples for materials for us in fire barriers include aramids, including para-aramids (poly(p-phenylene terephthalamide), e.g., KEVLAR® (E. I. Dupont) and TWARON® (Teijin Twaron BV) and meta-aramids (poly(m-phenylene isophthalamide), such as Nomex® (E.I. Dupont); fiberglass; melamines such as BASOFIL® (BASF); poly-benzimidazole (PBI) (Celanese Acetate A.G); oxidized polyacrylonitrile (PAN); novoloids, such as KYNOL®. (American Kynol, Inc); pre-oxidized fibers and carbon fibers, modacrylics, such as, e.g., KANECERON® and PROTEX® (Kaneka), FR (fire- or flame-resisting, -resistant, -retarding or -retardant) rayon, FR viscose, such as, e.g., VERIFIBER® TCF FR Rayon (Ventex, Inc.) and LENZING FR® (Lenzing AG, Fibers Division), wool and FR-treated cotton. It should be noted that these fibers are merely exemplary, and other fire-retardant fibers that form a char, including fibers that are developed in the future may be used. Additionally, certain proprietary modacrylic fibers that release extinguishing/oxygen depriving elements such as antimony when exposed to an ignition source may be used. This chemical reaction may assist in snuffing out small flames that may occur on adjacent, non-FR components such as the mattress covering fabric or ticking. Blends that include at least one fire-retardant fiber that form a char may also be used. The blends may include one or more structure-providing char-forming fire-retardant fibers, FR-treated fibers, such as FR-treated polyester, and non-FR fibers. Accordingly, either the fibers themselves may have a chemical structure that provides flame retardant characteristics or the fibers may include an additive that separately provides flame-retardant characteristics. Such additives may specifically serve to coat the fibers and provide a surface treatment and/or be dispersed within a given fiber network. Exemplary additives include polyphosphate compounds including polyphosphate emulsions, inorganic salts, aluminum oxides (e.g. Al2O3), boric acid compounds and/or halogen compounds.
The fire barrier element of the mattress may be provided by woven, knitted textile or non-woven. Examples of possible woven structures have been provided herein, and the types of knitted structures may include circular and warp knits, weft inserted knits, rib knits, jersey knits, interlock knits, double-knits, fleece knits, velour knits,
Non-woven fabrics may utilize a number of methods for maintaining the fibrous structures as well as joining more than a single fabric layer. Exemplary chemical bonding methods may include the use of adhesives, such as adhesive fibers, bi-component fibers or adhesive coatings that may be applied via powder coating, spray coating, baths, etc. Exemplary thermal bonding methods may include the use of low melting point fibers, bi-component fibers, point bonding, ultrasonic bonding, etc. Exemplary mechanical bonding may include carding, needle-punching, air-jet bonding, water-jet bonding, etc. In addition, the non-woven fabric for use may be three-dimensionally deformed via thermo-mechanical processes to form three-dimensional compressible features.
Further, the nested, zipperless mattress ticking assembly of the present disclosure may comprise an elastic fibrous assembly. As used herein the elastic fibrous assembly is the combination of constituent fibers or fibrous components that have been fitted together to form a structure that exhibit recovery when a mechanical stress is applied to the structure and subsequently released. In particular an elastic nonwoven structure or weft-type circular knitted textile structure may be an elastic fibrous assembly. The elastic fibrous assembly may utilize a number of methods to intermingle elastic materials with fibrous assembly fire blocking materials. The elastic materials may be impregnated into, disposed or sprayed on, laminated or intermingled with fire blocking materials.
Elastic or elastomeric materials used herein may include for example, elastomeric polymers, such as polyurethane, chloroprene, etc. Polyurethane may include spandex fiber which may be understood to include segmented polyurethane, Spandex®, Dorlastan®, Lycra®, polychloroprene (a type of synthetic rubber also known as neoprene and other elastomeric type polymers that may include polyisoprene, polybutadiene, polystyrene-butadiene and silicones.
The individual component materials used to construct a mattress may be drawn from the wide range of compositional and design approaches presently employed in the fields of mattress and upholstered furniture manufacturing without departing from the benefits being provided by the present disclosure. For instance, the use of antimicrobial treatments or finishes, such as those intended to mitigate or prevent bacterial or fungal growth, to provide odor-control or other similar benefits, on mattresses and upholstered furniture articles, including the fibers, yarns, filling materials, and foams, used to construct the mattresses or upholstered furniture articles would be anticipated by the present disclosure Other treatments or finishes, such as those intended to mitigate or prevent staining, soiling, moisture vapor penetration, moisture penetration, fluid penetration, or static electricity buildup are similarly anticipated.
The present disclosure does not seek to limit the myriad of materials that may utilized to form the textiles that could be used to fashion any of the elements disclosed herein. Rather it is anticipated that the design approach of the present disclosure is suitably novel and flexible to employ any fiber, yarn or product derived from such fibers or yarns to that is known to mattress manufacturers and customarily and reasonably used by mattress or upholstered furniture manufacturers to be sufficient to withstand the use demands, regulatory performance requirements and aesthetic desires of consumers.
In the context of the embodiments of the present disclosure, terms relating to mattresses are defined in conformity with terms as defined by 16 C.F.R. 1632, and as follows:
(a) Mattress means a ticking filled with a resilient material used alone or in combination with other products intended or promoted for sleeping upon.

- (1) This definition includes, but is not limited to, adult mattresses, youth mattresses, crib mattresses including portable crib mattresses, bunk bed mattresses, futons, water beds and air mattresses which contain upholstery material between the ticking and the mattress core, and any detachable mattresses used in any item of upholstered furniture such as convertible sofa bed mattresses, corner group mattresses, day bed mattresses, roll-a-way bed mattresses, high risers, and trundle bed mattresses. See Sec. 1632.8 Glossary of terms, for definitions of these items.
  - (2) This definition excludes sleeping bags, pillows, mattress foundations, liquid and gaseous filled tickings such as water beds and air mattresses which do not contain upholstery material between the ticking and the mattress core, upholstered furniture which does not contain a detachable mattress such as chaise lounges, drop-arm love seats, press-back lounges, push-back sofas, sleep lounges, sofa beds (including jackknife sofa beds), sofa lounges (including glide-outs), studio couches and studio divans (including twin studio divans and studio beds), and juvenile product pads such as car bed pads, carriage pads, basket pads, infant carrier and lounge pads, dressing table pads, stroller pads, crib bumpers, and playpen pads. See Sec. 1632.8 Glossary of terms, for definitions of these items.

(b) Mattress Pad means a thin, flat mat or cushion, and/or ticking filled with resilient material for use on top of a mattress. This definition includes, but is not limited to, absorbent mattress pads, flat decubitus pads, and convoluted foam pads which are totally enclosed in ticking. This definition excludes convoluted foam pads which are not totally encased in ticking.
(c) Ticking means the outermost layer of fabric or related material that encloses the core and upholstery materials of a mattress or mattress pad. A mattress ticking may consist of several layers of fabric or related materials quilted together.
(d) Core means the main support system that may be present in a mattress, such as springs, foam, hair block, water bladder, air bladder, or resilient filling.
(e) Upholstery material means all material, either loose or attached, between the mattress or mattress pad ticking and the core of a mattress, if a core is present.
(f) Tape edge (edge) means the seam or border edge of a mattress or mattress pad.
(g) Quilted means stitched with thread or by fusion through the ticking and one or more layers of upholstery material.
(h) Tufted means buttoned or laced through the ticking and upholstery material and/or core, or having the ticking and upholstery material and/or core drawn together at intervals by any other method which produces a series of depressions on the surface.” (16CFR1632.2).
(r) Mattress foundation. Consists of any surface such as foam, box springs or other, upon which a mattress is placed to lend it support for use in sleeping upon.” (16CFR1632.8).
Additionally, in the context of the present disclosure, these terms are further defined in conformity with terms as defined by the Consumer Product Safety Commission, 16 CFR Part 1633, Standard for the Flammability (Open Flame) of Mattress Sets; Final Rule—published in the Federal Register, Mar. 15, 2006.
Another aspect of the present disclosure relates to its use in articles of upholstered furniture. In the context of the present disclosure, terms relating to upholstered furniture are defined in conformity with terms as defined by the draft language of 16 C.F.R. 1634, as published by the CPSC in May 2005, and incorporated in their entirety herein by reference.
Another aspect of the present disclosure relates to its use in other articles filled with resilient cushioning materials. In the context of the present disclosure, terms relating to filled articles and bedding are defined as follows in conformity with the terms defined by the California BHFTI draft of Technical Bulletin #604 published Oct. 1, 2004, and the ANPR for 16 CFR 1634 Standard To Address Open Flame Ignition of Bedclothes published by the CPSC in the Federal Register on Jan. 13, 2005, pages 2514 through 2517, and incorporated in their entirety herein by reference.
The mattress that is intended to be covered by the ticking assembly disclosure disclosed herein is not intended to be limited and may be of any type, dimension, and/or shape. For example, the mattress may be a foam mattress, a coiled mattress, a foam and coil mattress, an air mattress, combinations thereof, or the like. Typically, the mattress is square or rectangular-shaped and has a thickness ranging from about 4 inches to about 20 inches. The length and width can vary depending on the intended application and typically has a width of about 2 feet to about 7 feet and a length of about 4 feet to about 10 feet, although custom sizes may require smaller or larger dimensions.
Said mattress while typically being square or rectangular, may also take any other shape, including but not limited to round, triangular, oblong, trapezoidal, or elliptical.
The interior elements of the mattress, customarily referred to as the mattress “core” may be formed of foam or a combination of foam and coils springs. The foam, in some embodiments, can be a monolithic block of a single type of resilient foam selected from foams having a range of densities (themselves well-known in the art) for supporting one or more occupants during sleep. In one embodiment, foam core is made of any industry-standard natural and/or synthetic foams, such as (but not limited to) latex, polyurethane, or other foam products commonly known and used in the bedding and seating arts having a density of 1.0 to 5.0 and 10 to 60 ILD. Although a specific foam composition is described, those skilled in the art will realize that foam compositions other than one having this specific density and ILD can be used. For example, foams of various types, densities, and ILDs may be desirable in order to provide a range of comfort parameters to the end user consumer. Additionally, the combining of individual layers of foam with varying, ascending, descending or undulating densities and ILDs may be deemed beneficial and are fully anticipated by the present disclosure. Furthermore, in addition to possibly of layering different foams, the mattress could be comprised of different blocks of foams with different combinations of densities and ILDs. These different blocks could be located in areas of the mattress that correspond to the areas of support by different parts of the body that sleeps on the mattress. For instance the areas of the body that typically require the greatest support such as the buttocks/hip and the shoulders/torso area could have foam blocks placed in areas of the mattress where those body parts would be expected to reside with appropriate densities and ILD combinations, while the body areas requiring less support could be satisfied with blocks featuring densities and ILD designed to match those support and cushioning requirements.
Certain components of a mattress, such as, for example, springs and/or a mattress topper may become worn before other components of the mattress. It would thus be beneficial to provide a mattress that allows some components to be replaced without replacing the entire mattress. Indeed, replacing the springs of a mattress, for example, without replacing other components of the mattress would significantly reduce the cost to the user who would otherwise have to buy a new mattress if the springs become worn or otherwise in need of replacement. An additional benefit to be derived from promoting and facilitating the end-consumer's ability to selectively replace any of the mattress components contained within the ticking assembly is that the waste stream impact of product disposal is reduced to only the targeted parts and the remaining parts are given extended service life.
Accordingly, this disclosure is directed to customizable mattresses that include variable components that allow a sleeper to create a mattress that has performance characteristics specifically tailored to the sleeper's body type and/or sleep preferences while also allowing the sleeper to replace the variable components with other variable components over time should the variable components become worn and/or the sleeper's body type or sleep preferences change over time.
Removable ticking assemblies have been employed in the construction of mattresses, however such assemblies have universally employed zippers as a means to join, attach and close multiple elements of the ticking assembly to one another. The use of zippers in the construction of the ticking assembly creates a variety of design deficiencies that are overcome by the present disclosure.
First, zippers of satisfactory quality are expensive. Elimination of the zipper can save money for the manufacturer and the end consumer.
Second, zippers present a potential breach point in the fire protection design of the mattress as they are not typically fashioned from flame resistant materials and those zippers that are so fashioned of flame resistant materials are substantially more expensive than the traditional zippers that the present design eliminates.
Third, to overcome the breach point of the zipper in the fire protection design, many mattress ticking assemblies that are made with zippers place a flame retardant fabric flange behind the zipper, however this flap of fabric is challenging to place correctly to encourage accurate installation and preservation of the placement necessary to overcome the breach point. The present disclosure does not require a flange to protect the interior mattress elements from ignition sources.
Fourth, zippers are prone to failure as evidenced by more than 7,000 videos posted on the YouTube internet video streaming service that offer advice of how to fix a broken zipper. The absence of the zipper from the ticking assembly precludes this potential failure point.
Fifth, the closing of the zipper can be a time-intensive and laborious process for an individual in order to ensure proper alignment and orientation of the zipper as well as the time required to exercise care to ensure that fabric elements of the ticking assembly do not become snagged, entrapped or damaged by the zipper closing process. The “pop-on” nature of the present disclosure does not require the end user to line up and slowly and methodically close a zipper and eliminates the potential for the ticking assembly or user to be damaged or injured by the zipper closing process.
Sixth, zippers have typically been viewed only as an adjunct part of the products into which they are sewn as a result the manufacturers of zippers have been driven to utilize the lowest cost materials, which have heretofore been predominantly polyester. As virtually all manufactured polyester contains antimony, zippers made from polyester contain antimony, a known carcinogen, and the elimination of zippers in the present disclosure serves to be a tool to enable consumers to eliminate the presence of a potentially toxic substance from their mattresses and by extensions their homes.
Good sleep is widely believed to be critical in enabling people to feel and perform their best, in all aspects of their lives. Sleep is routinely touted by medical professionals as being essential for improved health. Good sleep has been shown to affect numerous aspects of everyday life, from the ability of students to commit new information to memory to preventing weight gain. Because of the myriad of important benefits to be derived from good sleep, it is essential for people to have mattresses and bedding that match their personal sleep preference and are suited to their body type in order for them to enjoy comfortable, restful, beneficial sleep.
The 2012 “Bedroom Poll” conducted by the National Sleep Foundation (NSF), determined that 92% of nearly 1,500 rated that having a comfortable mattress was an important determinant in getting a good night's sleep. Those findings, which can be found at the NSF website, www.sleepfoundation.org, are incorporated herein by reference.
The human body may change over time. Sleeper may lose or gain weight. The change in weight may be slight or significant. When the change in weight is significant, it may affect the type of bedding the sleeper requires to achieve restful sleep. For example, a significant gain in weight may require that a sleeper use a firmer mattress, to provide support for the added weight. Conversely, a material weight loss can similarly affect the consumer's reaction to the comfort and feel of the mattress cushioning elements.
The sleeper's sleep preference may also change over time. For example, a sleeper who typically likes to sleep on their back may, over time, prefer to sleep on his or her side. The change in sleep preference may affect the type of bedding the sleeper requires to achieve restful sleep. For example, a sleeper changing from a back sleeper to a side sleeper may require that the sleeper use a firmer mattress.
The firmness and degree of support provided by a mattress can be influenced by the selection of the cushioning materials used to build a mattress. In the DTC selling model, the innerspring units historically found in the vast majority of mattresses have been mostly replaced by layers of foam that have been glued together. The most prevalent type of cushioning material used is foam, however foams come in a wide range and variety of compositions and the preparation of the foams can be altered to deliver differing densities as well as differing levels of firmness.
The Polyurethane Foam Association provides a teaching aid for understanding the technical terms related to flexible polyurethane foam (FPF) on their website at http://www.pfa.org/ce/handout2.html and the following definitions are well-known to those skilled in the art. These definitions have also been widely adopted for referring to the physical properties of foams of other compositions including gel foams, synthetic and natural latex foams and blends thereof,
Density—A measurement of the mass per unit volume. It is measured and expressed in pounds per cubic foot (pcf) or kilograms per cubic meter (kg/m3).
Indentation Force Deflection (IFD)—A measure of the load bearing capacity of flexible polyurethane foam. IFD is generally measured as the force (in pounds) required to compress a 50 square inch circular indentor foot into a four inch thick sample, typically 15 inches square or larger, to a stated percentage of the sample's initial height. Common IFD values are generated at 25 and 65 percent of initial height.
Support Factor (Compression Modulus)—Support Factor=65% IFD, 5% IFD determined after one minute of rest or recovery. When the support factor is known it can be used in conjunction with a known 25% IFD value to determine the 65% IFD value. Seating foams with low support factor are more likely to bottom out under load.
Flex Fatigue (Dynamic Fatigue)—A softening or loss of firmness. In general, fatigue is measured in the laboratory by repeatedly compressing a foam sample and measuring the change in IFD. Several different protocols, including methods contained in ASTM, ISO, and BIFMA testing standards, may be used. Even ASTM 3574, one of the more widely used sets of testing standards, contains multiple testing methods. In selecting one or more test methods, it is important to consider the intended foam application and to choose a testing protocol that closely simulates the intended application.
Tear Strength—A measure of the force required to continue a tear in a foam after a split or break has been started and expressed in pounds per inch (lb./in.). This property is important in determining suitability of foam in applications where the material is sewed, stapled, or otherwise anchored to a solid substance.
Resilience—An indicator of the surface elasticity or “springiness” of foam. It is measured by dropping a steel ball onto the foam cushion and measuring how high the ball rebounds.
Hysteresis—Measurement of a foam's ability to maintain original support characteristics after flexing. Normally, the firmness (IFD) is tested at 25% indentation, 65% indentation and again at 25% on the way up. Hysteresis is the percent of 25% IFD loss measure as a compression tester returns to the normal (25% IFD) position after measuring 65% compression. Lower hysteresis values, or less IFD loss are desirable. Current research indicates that hysteresis values may provide a good indication of overall flexible foam durability. Low hysteresis in conventional foam is equal to less IFD loss in durability and fatigue tests.
Air Flow—Amount of air expressed in cubic feet per minute, that can be drawn through a 2″×2″×1″ foam sample at 0.5-inch water pressure differential. Air Flow is measured by a test. High air flow equates to very open foam while low air flow tends to be pneumatic. Air flow can be a critical factor in FPF performance depending on the application. For instance, in normal furniture cushioning applications, a pneumatic foam with low air flow will have poor durability and high compression sets, regardless of density. However, in a packaging foam, a foam with minimal airflow may be desirable as a shock absorber, or in medical applications, slow recovery foams are used to improve patient care. Low air flow foams are also used in gasketing applications in air conditioning and heating.
Details on the laboratory procedures used to measure FPF performance properties can be found in ASTM 3574, which is incorporated herein by reference, and in other testing standards such as those promulgated by ISO and BIFMA. Also, to make a fair comparison of FPF sample properties, the same test methods and testing conditions must have been applied.
Certain materials used in the construction of a mattress, such as, for example, the resilient cushioning materials (foams) and textile components (such as the tickings and fire barrier fabrics) may wear out over time before some of other materials used to build the mattress. It would be beneficial, both from a cost perspective as well as an environmental impact perspective, to provide mattress designs that allow some components to be replaced without replacing the entire mattress. Replacing a foam layer of a mattress that has suffered from body impressions being formed in the foam, for example, without replacing other components of the mattress would significantly reduce the cost to the user who would otherwise have to buy a new mattress if the foam or cover become worn or otherwise in need of replacement and could not separately be replaced.
Additionally, a mattress ticking assembly with a modular design approach such as that depicted by the present disclosure would afford the end-user with the ability to replace a soiled ticking element without disposing of the entire mattress or entire ticking assembly itself.
The benefits of such a modular design would be a strong selling point to the DTC selling model and some DTC manufacturers have begun to offer products with such modularity focused design attributes.
Additionally the modular nature of said design approach would help overcome a primary deficiency of the DTC selling model, notably that the consumer cannot feel or try-out the mattress in advance of purchase. The modularity aspect permits the end-user, consumer and the mattress manufacturer to engage in a process to alter the feel of the mattress through a variety of change scenarios related to the structural, cushioning elements. One scenario would be the resequencing of structural cushioning elements in the mattress from the orientation originally provided to the consumer. An alternate scenario would be through the introduction of additional, new and possibly dissimilar structural, cushioning elements to the assortment of structural, cushioning elements than those that were originally provided to the consumer. A third scenario could be through the removal and replacement of a cushioning element not matched to consumer, end-user comfort preferences with a cushioning element that is preferred.
The mattress itself is not intended to be limited and may be of any type, dimension, and/or shape. For example, the mattress may be a foam mattress, a coiled mattress, a foam and coil mattress, an air mattress, combinations thereof, or the like. Typically, the mattress is square or rectangular-shaped and has a thickness ranging from about 4 inches to about 20 inches. The length and width can vary depending on the intended application and typically has a width of about 2 feet to about 7 feet and a length of about 4 feet to about 10 feet, although custom sizes may require smaller or larger dimensions.
Mattresses are regulated by the Federal Government with regards to their flammability and additionally are subject to numerous state and local regulations with regards to their manufacture, composition and labelling.
The Federal Flammability Act 16 C.F.R. Part 1632 was originally established to provide a federal flammability standard for bedding mattresses to reduce the chance and size of accidental fires caused by a cigarette or some form of smoldering heat source coming into contact with the bedding mattresses. The Consumer Product Safety Commission (“CPSC”) recognized this flammability standard was inadequate due a significant number of mattress fires that were the result of some form of open fuel source.
In October 2001, working in conjunction with the National Institute for Safety and Technology (“NIST”), the CPSC issued an advance notice of proposed rulemaking (“ANPR”) concerning the open flame ignition of mattresses/bedding to broaden the standard to include some form of open fuel source requirement. These flammability standards were researched and in 2005 the CPSC issued a notice of proposed rulemaking (“NPR”) proposing a flammability standard based on the NIST research.
The characteristics of mattress/bedding fires and research conducted to develop the standard are discussed in detail in the NPR, 70 F.R. 2470, incorporated herein by reference in its entirety. The final rule was enacted in March of 2006 as 16 C.F.R. Part 1633 entitled Standard for the Flammability (Open Flame) of Mattress Sets (hereinafter the “1633 flammability standard”) as published in the Federal Register/Vol. 71, No. 50. Mar. 15, 2006/Rules and Regulations, incorporated herein by reference in its entirety. The 1633 flammability standard applies to mattresses and mattress and foundation sets (“mattress sets”). A “Mattress” is defined as a resilient material, used alone or in combination with other materials, enclosed in a ticking and intended or promoted for sleeping upon.
In recent years, there has been remarkable growth in the number of mattress companies that have eschewed traditional approaches of displaying mattresses, allowing customers to evaluate mattress comfort and selling mattresses in “brick and mortar” mattress stores and showrooms in favor of selling their products over the internet and delivering the products direct to the consumer (DTC). These mattresses are typically compressed, sealed in plastic to hold the compression, rolled and then stuffed in packaging that permits the mattresses to be shipped by courier services such as United Parcel Service, Federal Express or DHL. The consumer is responsible for unpackaging the mattress and placing it in their desired sleeping space.
By removing the sales margin of a retailer and removing the distribution costs associated with the transportation and installation of traditional mattresses that cannot be compressed, rolled and boxed, the DTC selling model is able to deliver a higher perceived value to the end consumer as mattresses of a specific construction can be sold at prices that are substantially lower than those sold through traditional “brick and mortar” selling models. One particularly well-known example of the success of this DTC selling model approach is Casper, the internet-based mattress company that has grown in less than three years to an estimated $200 million dollars of sales per year on sales of roughly 200,000 mattresses per annum. Other examples include Leesa, Tuft & Needle, Cocoon by Sealy, Purple, Yoga Bed, Helix, and Luxi to name a few. Notably all of these manufacturers either use zippers to close their ticking assemblies or employ ticking assemblies that are permanently closed with sewn seams.
The use of zippers adds manufacturing cost that the present disclosure eliminates, the prospect of zipper failure that renders the entire ticking assembly worthless and opening or closing time and struggles that are not present with the simplified installation profile of the present disclosure.
The DTC selling model does not afford the consumer with the opportunity to feel the mattress or personally judge the comfort of the mattress they are purchasing until after it arrives at their residence, is opened and installed.
In the DTC selling model, consumers are typically given several months or more to evaluate the mattress for comfort and satisfaction. If they decide that they do not like the mattress, they are typically given a full refund and the mattress is donated to a charity by the mattress manufacturer.
Some mattress manufacturers utilizing the DTC selling model have attempted to address the reported 10% rejection rate in a variety of ways. Some manufacturers provide the customer with slabs of topper foam or other cushioning materials that are different in feel from the mattress's original design and that are intended to be placed on top of the actual mattress to alter the feel of the bed. Others, such as Novosbed (www.novosbed.com), attempt to alter the feel of the mattress to satisfy the consumer by providing a foam insert that is put into the inside of the mattress but requires the consumer to install a zippered expansion panel to allow the mattress ticking assembly to accommodate the additional height of the added piece of cushioning.
In addition to the benefits to be derived from the present invention by the elimination of zippers, preferred embodiments offer additional benefits as well, most notably with regards to promoting designs that facilitate laundering of the removable, nested, zipperless mattress ticking assembly.
Many mattress ticking assemblies use different fabrics on the top and bottom elements of the assembly. In many cases the tickings on the top are predominantly knitted fabrics and the fabrics on the bottom are predominantly non-woven or stitch-bonded fabrics.
Different textile constructions and compositions respond differently to laundering factors such as washing temperature, drying temperature, detergent compositions and the like. These factors can affect the degree to which textiles shrink from their original size, change the feel or hand of the material or negatively impact the performance aspects of the fabrics as it relates to such dimensions as flame retardance or anti-microbial performance. In order to mitigate the potentially adverse consequences of laundering on the performance attributes of the materials used to construct the mattress ticking assembly, the material selection process should be structured to select products that will fare positively when laundered to promote the fullest range of benefits available.
Mattress tickings are likely to become soiled during their service lives by a wide range of substances. Consumers will be inclined to attempt to launder these tickings if the design promotes their removal from the mattress core assembly, even despite possible warnings by manufacturers against laundering.
The laundering process can cause a wide variety of outcomes that would be viewed as adverse by the end-user, consumer. The use of different fabrics in a traditional ticking assembly made with a zipper may result in varying degrees of material shrinkage during laundering that may cause a cover to be ill-fitting or non-fitting or non-closeable after the laundering process.
Even if laundering is not discouraged by the mattress manufacturer, the physical size of a ticking assembly that is not able to be physically separated may preclude the ability to fit it into many washing machines or dyers that consumers have in their homes. The preferred embodiment of the present invention is for a mattress ticking assembly that is in two, separate and nested parts. These separate parts are therefore, comprised of less aggregate material than a complete mattress ticking assembly that is not fully separable into multiple parts and may be of a size more easily accommodated by typical washers and dryers.
It is to be understood that the above description is intended to be illustrative, and not restrictive. Numerous changes and modifications may be made herein by one of ordinary skill in the art without departing from the general spirit and scope of the disclosure as defined by the following claims and the equivalents thereof. For example, the above-described embodiments (and/or aspects thereof) may be used in combination with each other. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the various embodiments without departing from their scope. While the dimensions and types of materials described herein are intended to define the parameters of the various embodiments, they are by no means limiting and are merely exemplary. Many other embodiments will be apparent to those of skill in the art upon reviewing the above description. The scope of the various embodiments should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. In the appended claims, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects. Also, the term “operably” in conjunction with terms such as coupled, connected, joined, sealed or the like is used herein to refer to both connections resulting from separate, distinct components being directly or indirectly coupled and components being integrally formed (i.e., one-piece, integral or monolithic). Further, the limitations of the following claims are not written in means-plus-function format and are not intended to be interpreted based on 35 U.S.C. § 112, sixth paragraph, unless and until such claim limitations expressly use the phrase “means for” followed by a statement of function void of further structure. It is to be understood that not necessarily all such objects or advantages described above may be achieved in accordance with any particular embodiment. Thus, for example, those skilled in the art will recognize that the systems and techniques described herein may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other objects or advantages as may be taught or suggested herein.
While the disclosure has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the disclosure is not limited to such disclosed embodiments. Rather, the disclosure can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the disclosure. Additionally, while various embodiments have been described, it is to be understood that aspects of the disclosure may include only some of the described embodiments. Accordingly, the disclosure is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims.
This written description uses examples, including the best mode, and also to enable any person skilled in the art to practice the disclosure, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.

Claims

1. A mattress assembly comprising:

a mattress core assembly having a top side, a bottom side, and a peripherally-extending side disposed between said top side and said bottom side; and

a nested, zipperless mattress ticking assembly for covering said mattress core assembly, said nested, zipperless mattress ticking assembly comprising:

an upper mattress ticking assembly comprising a top side extending over said top side of said mattress core assembly and a peripheral portion extending over a portion of said peripherally-extending side of said mattress core assembly;

a lower mattress ticking assembly comprising a bottom side extending over said bottom side of said mattress core assembly and a peripheral portion extending over a portion of said peripherally-extending side of said mattress core assembly;

said peripheral portions of said upper and lower mattress ticking assemblies overlap each other along said peripherally-extending side of said mattress core assembly; and

wherein said mattress assembly meets the flammability standards of the 16 CFR 1633.

2. The mattress assembly of claim 1 wherein said nested, zipperless mattress ticking assembly alone provides flame resistant properties necessary for the mattress assembly to meet the flammability standards of the 16 CFR 1633.

3. The mattress assembly of claim 1 wherein said mattress core assembly comprises one or more fire barrier interliners covering said mattress core assembly provides flame resistant properties necessary for the mattress assembly to meet the flammability standards of the 16 CFR 1633.

4. The mattress assembly of claim 1 wherein said mattress core assembly comprises one or more fire barrier interliners covering said mattress core assembly and said nested, zipperless mattress ticking assembly in combination together are operable to provide flame resistant properties necessary for the mattress assembly to meet the flammability standards of the 16 CFR 1633.

5. The mattress assembly of claim 1 wherein said top side of said upper mattress ticking assembly comprises a plurality of textile materials that are quilted or joined together to form a unitary fabric.

6. The mattress assembly of claim 1 wherein said top side of said upper mattress ticking assembly comprises a plurality of fabric layers.

7. The mattress assembly of claim 1 wherein said upper mattress ticking assembly is thicker than said lower mattress ticking assembly.

8. The mattress assembly of claim 1 wherein said mattress core assembly comprises a single foam element.

9. The mattress assembly of claim 1 wherein said mattress core assembly comprises a plurality of foam elements.

10. The mattress assembly of claim 1 wherein said mattress core assembly comprises a first upper mattress core assembly disposed on a second lower mattress core assembly, said first mattress core assembly having a first top side, a first bottom side, and a first peripherally-extending side disposed between said first top side and said first bottom side, and a second mattress core assembly having a second top side, a second bottom side, and a second peripherally-extending side disposed between said second top side and said second bottom side, and wherein said upper mattress ticking assembly covers said first top side, said peripherally-extending sides of said first and second core, and a portion of the bottom side of said second core adjacent to the peripherally-extending edge.

11. The mattress assembly of claim 1 wherein said mattress core assembly comprises three or more mattress core elements comprising flexible foams arranged so that the IFD values of the flexible foams are sequenced so that the values on the outer surfaces are lower than the IFD values of the inner foam elements.

12. The mattress assembly of claim 1 wherein said mattress core assembly comprises springs.

13. The mattress assembly of claim 1 wherein said mattress core assembly comprises fibrous filling materials.

14. The mattress assembly of claim 1 wherein said mattress core assembly comprises air-filled bladders or containers.

15. The mattress assembly of claim 1 wherein said mattress core assembly comprises fluid-filled bladders or containers.

16. The mattress assembly of claim 1 wherein said top side of said upper mattress ticking assembly covers said upper side of the mattress core assembly, and said peripheral portion of said upper mattress ticking assembly covers said peripherally-extending side of said mattress core assembly and only a portion of said bottom side of the mattress core assembly adjacent to the peripherally-extending side of the mattress core assembly.

17. The mattress assembly of claim 16 wherein an edge of said peripheral portion of said upper mattress ticking assembly define an opening for receiving said mattress core assembly.

18. The mattress assembly of claim 17 wherein said upper mattress ticking assembly and said lower mattress ticking assembly are physically attached together.

19. The mattress assembly of claim 1 wherein said upper and said lower mattress tickings assemblies cover at least fifty-percent of the surface area of the mattress core assembly.

20. The mattress assembly of claim 1 wherein said upper and said lower mattress tickings assemblies cover the entire surface area of the mattress core assembly.

21. The mattress assembly of claim 1 wherein said peripheral portion of said upper mattress ticking assembly and said peripheral portion of said lower mattress ticking assembly extend along the entire length of said peripherally-extending side of said mattress core assembly.

22. The mattress assembly of claim 1 wherein said nested, zipperless mattress ticking assembly comprises elastomeric properties.

23. The mattress assembly of claim 1 wherein at least a portion of said nested, zipperless mattress ticking assembly comprises a knitted fabric.

24. The mattress assembly of claim 23 wherein said knitted fabric comprises an elastic polyurethane material.

25. The mattress assembly of claim 1 wherein said peripheral portion of said upper mattress ticking assembly comprises an elastic material.

26. The mattress assembly of claim 1 wherein said peripheral portion of said lower mattress ticking assembly comprises an elastic material.

27. The mattress assembly of claim 1 wherein said upper and said lower mattress ticking assemblies are not connectable to one another.

28. The mattress assembly of claim 1 wherein said upper and said lower mattress ticking assemblies are releasably attachable to one another.

29. The mattress assembly of claim 1 wherein said upper and said lower mattress ticking assemblies are fixedly attached to one another.

30. The mattress assembly of claim 29 wherein said upper and said lower mattress ticking assemblies are at least partially attached to one another with sewn seams, snaps and/or buttons.

31. The mattress assembly of claim 1 wherein said lower mattress ticking assembly covers said bottom side of said mattress core assembly, said peripherally-extending side of said mattress core assembly, and only a portion of the upper side adjacent to the peripherally-extending side of the mattress core assembly.

32. The mattress assembly of claim 10 wherein said bottom ticking covers said bottom side and said peripherally-extending side of said second mattress core assembly.

33. The mattress assembly of claim 32 wherein said bottom ticking covers a portion of said first top side of said second mattress core assembly adjacent to the peripherally-extending side of said second mattress core assembly.

34. A mattress assembly comprising:

a mattress core assembly having a top side, a bottom side, and a peripherally-extending side disposed between said top side and said bottom side;

an upper mattress ticking assembly comprising a top side extending over said top side of said mattress core assembly, a peripheral portion extending over said peripherally-extending side of said mattress core assembly, and a bottom side disposed under a portion of the bottom side of the mattress core; and

35. The mattress assembly of claim 34 wherein said top side of said upper mattress ticking assembly covers said upper side of the mattress core assembly, and said peripheral portion of said upper mattress ticking assembly covers said peripherally-extending side of said mattress core assembly and only a portion of said bottom side of the mattress core assembly adjacent to the peripherally-extending side of the mattress core assembly.

36. The mattress assembly of claim 35 wherein an edge of said peripheral portion of said upper mattress ticking assembly define an opening for receiving said mattress core assembly.

37. A method for forming a mattress assembly, the method comprising:

providing a mattress core assembly having a top side, a bottom side, and a peripherally-extending side disposed between the top side and the bottom side;

positioning a nested, zipperless mattress ticking assembly comprising an upper mattress ticking assembly and a lower mattress ticking assembly over the mattress core assembly, and portions of the upper mattress ticking assembly and the lower mattress ticking assembly overlapping each other; and

wherein the mattress assembly meets the flammability standards of the 16 CFR 1633.

38. The method of claim 37 wherein the positioning the nested, zipperless mattress ticking assembly comprises first positioning the upper mattress ticking assembly over the top side of the mattress core assembly and over a portion of the peripherally-extending side of the mattress core assembly, and second positioning the lower mattress ticking assembly over the bottom side of the mattress core assembly and over a portion of the peripherally-extending side of the mattress core assembly.

39. The method of claim 37 wherein a portion or portions of the upper mattress ticking assembly overlap the lower mattress ticking assembly.