Patent Application
20220296002
The present disclosure generally relates to mattress construction, and more particularly, to a flange perimeter construction for securing a border assembly along sidewalls of a mattress.
Mattress construction can involve assembling multiple layers of material to form the mattress. For example, a mattress may include a combination of one or more foam layers stacked atop one another to form a composite encasement. Each layer may be affixed to one another using an adhesive, such as a glue. Once the layers are in place, a side border assembly formed of a fabric material layer may be affixed to sidewalls along the perimeter of the mattress. In addition to providing a general aesthetic for the mattress, the border assembly serves several functions, including supporting the overall mattress construction. Particularly, the border assembly prevents layers from shifting and consequently coming out of alignment with the overall construction over extended use. As a result, the construction of the mattress remains even and straight along the edges.
Embodiments presented herein disclose a mattress having a flange construction for securing a border assembly. The flange construction is formed of a material (e.g., a non-woven polyester fiber, a fabric material, etc.) that is affixed along the perimeter of the mattress. The border assembly is formed of a material comprising several layers, including an exterior embroidered layer and one or more interior layers. The border assembly further includes a flap material for binding the border assembly to the flange construction. The flap material may be adhered to the flange construction using a substance such as a glue. A center support flange construction material may further be affixed across the perimeter to further secure the flap material and provide a center support for the border assembly. Once adhered, the border assembly may be sewn to the mattress via the flap material.
While the present disclosure may be susceptible to embodiment in different forms, there is shown in the drawings, and described herein in detail, embodiments with the understanding that the present description exemplifies principles of the disclosure and does not intend to exhaust or limit the disclosure to the details of construction and the arrangements of components set forth in the following description and illustrated in the drawings. The present disclosure is described in connection with one or more contemplated embodiments which are not intended to be limiting of the scope of the present disclosure. The present disclosure is intended to encompass those embodiments as well as equivalents and variations.
Embodiments presented herein disclose a mattress trimline construction and method for assembling same. Particularly, in assembly, a mattress having multiple layers includes a thin material strip (e.g., a non-woven polyester fiber, a fabric material) (referred to herein as a “flange construction”) that is affixed along a perimeter of an upper layer thereof. The flange construction receives a flap portion of a border assembly such that, when the border assembly is wrapped along a sidewall of the mattress, the flange construction more durably secures the border assembly along the sidewall.
Referring now to
In an embodiment, a flange construction 106 may be formed along the perimeter of the upper surface layer 102 of the mattress system 100. As shown, the flange construction 106 may comprise multiple portions of a material strip (e.g., a non-woven 100% polyester fiber material, cloth material, fabric material, etc.) (also referred to herein as a “flange material”) affixed (e.g., glued, sewn, stapled, and so on) along the perimeter of the upper surface layer 102 of the mattress system 100, extending from one edge of the mattress system and towards the center. The flange material may have a given length, e.g., approximately six inches. For example,
The flange construction 106 provides a support to allow a border assembly material to be attached to and further secured along the sidewall 104 of the mattress system 100.
Illustratively, the border assembly material 200 includes a flap material 308, which is a thin material that may be formed of, e.g., a cloth or fabric material and is attachable to the flange construction 106. The flap material 308 has an inner side that faces the interior layer 310 and an outer side facing the foam layer 306.
In the foregoing description, numerous specific details, examples, and scenarios are set forth in order to provide a more thorough understanding of the present disclosure. It will be appreciated, however, that embodiments of the disclosure may be practiced without such specific details. Further, such examples and scenarios are provided for illustration only, and are not intended to limit the disclosure in any way. Those of ordinary skill in the art, with the included descriptions, should be able to implement appropriate functionality without undue experimentation.
References in the specification to “an embodiment,” etc., indicate that the embodiment described may include a particular feature, structure, or characteristic. Such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is believed to be within the knowledge of one skilled in the art to effect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly indicated.
In the drawings, specific arrangements or orderings of elements may be shown for ease of description. However, the specific ordering or arrangement of such elements is not meant to imply that a particular order or sequence of assembly, or separation of processes, is required in all embodiments. Further, some connections, relationships, or associations between elements may be simplified or not shown in the drawings so as not to obscure the disclosure.
This disclosure is considered to be exemplary and not restrictive. In character, and all changes and modifications that come within the spirit of the disclosure are desired to be protected. While particular aspects and embodiments are disclosed herein, other aspects and embodiments will be apparent to those skilled in the art in view of the foregoing teaching.
While the foregoing is directed to embodiments of the present disclosure, other and further embodiments of the disclosure may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.
