MATTRESS ENCASEMENT

Abstract

A mattress incudes a core and an encasement sized and shaped to receive the core. The encasement includes a first end, a second end, a first side, a second side, an upper portion, a lower portion, an interior portion, an opening at the first end and in communication with the interior portion, and a flap at the first end. The flap is moveable from an open position, in which the flap is outside of the opening, and a closed position, in which the flap is within the opening. The flap overlays at least a portion of the core when the flap is in its closed position.

Description

FIELD OF THE INVENTION

The present invention relates to a mattress encasement and, more particularly, a mattress encasement for a mattress core.

BACKGROUND

Mattresses sold in the United States must meet specific government flame resistant safety standards. This standard is governed under the federal government's CPSC's CFR 1633 and CFR 1632 testing criteria and requirements. A variety of materials, applications, and designs are incorporated into mattress manufacturers finished product designs to adhere to and comply with the required standards. One such design is the use of an inner encasement or covering that is produced with a variety of material specifications. This inner encasement is commonly known throughout the mattress industry as a “flame resistant sock.”

SUMMARY

In some embodiments, a mattress includes a core; and an encasement, wherein the encasement includes a first end, a second end opposite the first end, a first side, a second side opposite the first side, an upper portion, a lower portion opposite the lower portion, an interior portion, an opening at the first end and in communication with the interior portion, and a flap at the first end, wherein the core is within the interior portion, wherein the flap is moveable from an open position, in which the flap is outside of the opening, and a closed position, in which the flap is within the opening, and wherein the flap overlays at least a portion of the core when the flap is in its closed position.

In some embodiments, the core includes a first end, a second end opposite the first end of the core, a first side, a second side opposite the first side, an upper surface, and a lower surface opposite the upper surface, wherein when the flap is in its closed position, the flap covers the first end of the core, at least a portion of the upper surface of the core, and at least a portion of the lower surface of the core. In some embodiments, the core includes first corner edge extending from the upper surface to the lower surface at an intersection of the first end and the first side, and a second corner edge extending from the upper surface to the lower surface at an intersection of the first end and the second side, wherein when the flap is in its closed position, the flap covers the first corner edge and the second corner edge. In some embodiments, the flap includes a first end, a second end opposite the first end of the flap, a first side, a second side opposite the first side of the flap, a first surface extending from the first end of the flap to the second end of the flap and from the first side of the flap to the second side of the flap, and a second surface opposite the first surface of the flap, wherein the first surface of the flap covers the first end of the core when the flap is in its closed position. In some embodiments, a portion of the first surface of the flap is between the upper surface of the core and an interior surface of the lower portion of the encasement.

In some embodiments, the first end of the flap is integral with the first end of the encasement. In some embodiments, the second end of the flap is between the first end of the encasement and the second end of the encasement when the flap is in its open position. In some embodiments, the second end of the encasement is closed. In some embodiments, the first side of the flap is aligned with the first side of the encasement when the flap is in its open position, and wherein the second side of the flap is aligned with the second side of the encasement when the flap is in its open position. In some embodiments, the second end of the encasement overlays the second end of the core, wherein the first side of the encasement overlays the first side of the core, wherein the second side of the encasement overlays the second side of the core, wherein the upper portion of the encasement overlays the upper portion of the core, the lower portion of the encasement overlays the lower portion of the core.

In some embodiments, the core is composed of foam. In some embodiments, the encasement is composed of a fire retardant fabric.

In some embodiments, the opening of the encasement has a height of 5 inches to 20 inches. In some embodiments, the opening of the encasement has a width of 25 inches to 80 inches. In some embodiments, the opening extends from the first side of the encasement to the second side of the encasement and from the upper portion to the lower portion.

In some embodiments, method includes the steps of obtaining a mattress core encasement having an upper portion, a lower portion, an initial open end, a closed end opposite the open end, a first side extending from the open end to the closed end, and a second side opposite the first side and extending from the open end to the closed end; cutting a slit in each of the first side and the second side from the open end to a location between the open end to the closed end and by a length; folding back a portion of the upper portion onto itself to create a fold line; cutting an excess portion of the lower portion such that an end of the lower portion is substantially aligned with the fold line of the upper portion; and attaching the folded portion of the upper portion and the lower portion along the first side and the second side to create the opening on the initial open end of the encasement and a flap.

In some embodiments, method further includes stretching the folded back portion of the upper portion onto the upper portion prior to the cutting a slit in each of the first side and the second side. In some embodiments, the step of attaching the folded portion includes sewing. In some embodiments, the length is 10 inches to 20 inches.

In some embodiments, a method includes the steps of obtaining an encasement having an opening, a flap proximate to the opening, an upper portion, and a lower portion; obtaining a mattress core having a first end, an upper surface, and a lower surface; inserting the mattress core into the opening of the encasement; pulling the encasement over the core; pulling the flap over the core such that the flap fully covers the first end of the core; and inserting at least a portion of the flap between a lower surface of the core and an interior surface of the lower portion of the encasement.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1 and 2 are top perspective views of some embodiments of a mattress core and a mattress encasement;

FIG. 3 is a top perspective view of some embodiments of a mattress encasement in a relaxed state;

FIG. 4 is a top perspective view of some embodiments of the mattress encasement illustrated in FIG. 3 in an open or expanded state, with a flap employed by the mattress encasement in an open position;

FIG. 5 is a top perspective, exploded view of some embodiments of a mattress having a mattress core and the mattress encasement illustrated in FIG. 4; and

FIG. 6 is a top perspective view of the mattress illustrated in FIG. 5 with the flap employed by the mattress encasement in a closed position.

DETAILED DESCRIPTION

Referring to FIGS. 1 and 2, in some embodiments, a mattress 10 includes a core 12 and an encasement 14 that is fitted over the core 12. In some embodiments, the core 12 is composed of a foam. In some embodiments, the core 12 is composed of polyurethane foam (polyfoam). In some embodiments, the core 12 is composed of latex foam. In some embodiments, the core 12 is composed of latex foam derived from 100% natural materials and/or synthetic blends. In some embodiments, the core 12 is composed of any flexible polyurethane foam. In some embodiments, the core 12 is composed of any natural or synthetic fibers. In some embodiments, the core 12 is composed of foam having tradition or exotic chemistries. In some embodiments, the core 12 is composed of memory foam (viscoelastic polyurethane foam, or low-resistance polyurethane foam (LRPu). In some embodiments, the core 12 is composed of a hyper-elastic polymer material. In some embodiments, the core 12 comprises air chambers. In some embodiments, the core 12 is comprises predominantly of air chambers.

In some embodiments, the core 12 comprises springs. In some embodiments, the core 12 comprises coil springs. In some embodiments, the core 12 comprises Bonnell coils. In some embodiments, the core 12 comprises pocket coils. In some embodiments, the core 12 comprises offset coils. In some embodiments, the core 12 comprises continuous coils. In some embodiments, the core 12 comprises a hair block, water bladder, air bladder, or resilient filling. In some embodiments, the core 12 includes at least one layer. In some embodiments, the at least one layer includes a plurality of layers.

In some embodiments, encasement 14 is composed of a fabric. In some embodiments, the fabric is a flame resistant fabric or a fire-retardant fabric. In some embodiments, the fabric is configured to reduce consumption of the core 12 when burned during 1633 testing, resulting in lower kW and Megajoules. In some embodiments, the fabric includes a structure, function, composition and/or features similar to one or more embodiments disclosed in U.S. application Ser. No. 17/971,386 entitled “Fire Retardant Fabric,” published as U.S. Patent Application Publication No. 2023/0127723 on Apr. 27, 2023, which is incorporated by reference herein in its entirety. In some embodiments, the fabric includes a structure, function, composition and/or features similar to one or more embodiments disclosed in U.S. Pat. No. 11,286,593 to Martin et al. entitled “Flame Retardant Mattress Core Cap and Method of Making Same” and U.S. Pat. No. 10,563,328 to Martin et al. entitled “Flame Retardant Mattress Core Cap and Method of Making Same,” the contents of each of which is incorporated by reference in its entirety.

Referring to FIGS. 3 and 4, in some embodiments, the encasement 14 includes a first end 16, a second end 18 opposite the first end 16, a first side 20 extending from the first end 16 to the second end 18, and a second side 22 opposite the first side 20 and extending from the first end 16 to the second end 18. In some embodiments, the encasement 14 includes an upper, first portion 24 and a lower, second portion 26 opposite the first portion 24. In some embodiments, each of the first portion 24 and the second portion 26 includes an exterior surface and an interior surface. In some embodiments, the first portion 24 extends from the first end 16 to the second end 18 and from the first side 20 to the second side 22. In some embodiments, the second portion 26 extends from the first end 16 to the second end 18 and from the first side 20 to the second side 22. In some embodiments, the encasement 14 includes an opening 28. In some embodiments, the opening 28 is located at the first end 16. In some embodiments, the opening 28 extends from the first side 20 to the second side 22. In some embodiments, the opening 28 extends from the first portion 24 to the second portion 26. In some embodiments, the second end 18 is a closed end. In some embodiments, the encasement 14 includes an interior portion 29. In some embodiments, the opening 28 is in communication with the interior portion 29. In some embodiments, the interior portion 29 extends from the opening 28 to the second end 18 and from the first side 20 to the second side 22. In some embodiments, the interior portion 29 is sized and shaped to receive the core 12. In some embodiments, the encasement 14 is configured to encapsulate the core 12. In some embodiments, the encasement 14 is configured to encapsulate the core 12 in its entirety. In some embodiments, the encasement 14 is configured to substantially encapsulate the core 12. In some embodiments, the encasement 14 includes a length L1. In some embodiments, the length L1 is 54 inches to 130 inches.

In some embodiments, the opening 28 includes a height H1 when the encasement 14 is in an open or expanded position. In some embodiments, the height H1 is 5 inches to 20 inches. In some embodiments, the height H1 is 5 inches to 15 inches. In some embodiments, the height H1 is 5 inches to 10 inches. In some embodiments, the height H1 is 10 inches to 20 inches. In some embodiments, the height H1 is 10 inches to 15 inches. In some embodiments, the height H1 is 15 inches to 20 inches.

In some embodiments, the opening 28 includes a width W1. In some embodiments, the width W1 is 25 inches to 80 inches. In some embodiments, the width W1 is 30 inches to 75 inches. In some embodiments, the width W1 is 35 inches to 70 inches. In some embodiments, the width W1 is 40 inches to 65 inches. In some embodiments, the width W1 is 45 inches to 60 inches. In some embodiments, the width W1 is 50 inches to 55 inches. In some embodiments, the width W1 is 27 inches to 76 inches.

In some embodiments, the encasement 14 is configured to stretch in one or more directions. In some embodiments, the height H1 is configured to increase or change in size and shape when the encasement 14 is stretched. In some embodiments, the width W1 is configured to increase or change in size and shape when the encasement 14 is stretched.

In some embodiments, the encasement 14 includes a flap 30. In some embodiments, the flap 30 is located at the first end 16. In some embodiments, the flap is located proximate to the first end 16. In some embodiments, the flap 30 includes a first end 32, a second end 34 opposite the first end 32, a first side 36 extending from the first end 32 to the second end 34, and a second side 38 opposite the first side 36 and extending from the first end 32 to the second end 34. In some embodiments, the flap 30 includes a first, upper surface 40 and a second, lower surface 42 opposite the first surface 40. In some embodiments, the first end 32 of the flap 30 is integral with the first end 16. The second end 34 of the flap 30 is between the first end 16 of the encasement 14 and the second end of the encasement 14 when the flap 30 is in an open position. In some embodiments, the first side 36 of the flap 30 is aligned or substantially aligned with the first side 20 of the encasement 14 when the flap 30 is in the open position. In some embodiments, the second side 38 of the flap 30 is aligned or substantially aligned with the second side 22 of the encasement 14 when the flap 30 is in the open position. In some embodiments, the flap 30 has a width W2. In some embodiments, the width W2 is inches to 76 inches. In some embodiments, the width W2 is 25 inches to 75 inches. In some embodiments, the width W2 is 30 inches to 70 inches. In some embodiments, the width W2 is 35 inches to 65 inches. In some embodiments, the width W2 is 40 inches to 60 inches. In some embodiments, the width W2 is 45 inches to 55 inches.

Referring to FIGS. 5 and 6, in some embodiments, the core 12 includes a first end 44, a second end 46 opposite the first end 44, a first side 48 extending from the first end 44 to the second end 46, and a second side 50 opposite the first side 48 and extending from the first end 44 to the second end 46. In some embodiments, the core 12 includes a first, upper surface 52 and a second, lower surface 54 opposite the first surface 52. In some embodiments, the first surface 52 extends from the first end 44 to the second end 46 and from the first side 48 to the second side 50. In some embodiments, the second surface 54 extends from the first end 44 to the second end 46 and from the first side 48 to the second side 50. In some embodiments, a first corner edge 56 extends from the first surface 52 to the second surface 54 and at the intersection of the first end 44 and the first side 48. In some embodiments, a second corner edge 58 extends from the first surface 52 to the second surface 54 and at the intersection of the first end 44 and the second side 50.

In some embodiments, the interior portion 29 of the encasement 14 is sized and shaped to receive the core 12 through the opening 28 of the encasement 14. In some embodiments, the encasement 14 is configured to stretch and increase the size and/or shape of the interior portion 29 of the encasement 14 to receive the core 12. In some embodiments, second end 18 of the encasement 14 overlays and is juxtaposed with the second end 46 of the core 12. In some embodiments, first side 20 of the encasement 14 overlays and is juxtaposed with the first side 48 of the core 12. In some embodiments, the second side 22 of the encasement 14 overlays and is juxtaposed with the second side 50 of the core 12. In some embodiments, the first portion 24 of the encasement 14 overlays and is juxtaposed with the first surface 52 of the core 12. In some embodiments, the second portion 26 of the encasement 14 overlays and is juxtaposed with the second surface 54 of the core 12.

In some embodiments, the flap 30 is moveable from an open position, in which the flap 30 is outside of the opening 28 (see FIG. 5), and a closed position, in which the flap is inserted within the opening 28 (see FIG. 6). In some embodiments, the flap 30 is pulled over at least a portion of the core 12 when the flap 30 is in the closed position. In some embodiments, when the flap 30 is in the closed position, the flap 30 overlays, envelopes or covers the first end 44 of the core 12, at least a portion of the first surface 52 of the core 12, at least a portion of the second surface 54 of the core 12, the first corner edge 56, and the second corner edge 58. In some embodiments, the first surface 40 of the flap 30 covers or overlays the first end 44 of the core 12 when the flap 30 is in the closed position. In some embodiments, a portion of the first surface 40 of the flap 30 is between the first surface 52 of the core 12 and an interior surface of the second portion 26 of the encasement 14 when the flap 30 is in the closed position. In some embodiments, the core 12 is not visible external of the mattress 10 when the flap 30 is in the closed position.

In some embodiments, the mattress 10 is a crib mattress. In some embodiments, the mattress 10 is a portable crib mattress. In some embodiments, the mattress 10 is a small single mattress. In some embodiments, the mattress 10 is a twin mattress. In some embodiments, the mattress 10 is a twin XL mattress. In some embodiments, the mattress is a full mattress. In some embodiments, the mattress 10 is a full XL mattress. In some embodiments, the mattress 10 is a queen mattress. In some embodiments, the mattress 10 is an Olympic queen mattress. In some embodiments, the mattress 10 is a king mattress. In some embodiments, the mattress 10 is a California king mattress. In some embodiments, the mattress 10 is an adult mattress. In some embodiments, the mattress 10 is a youth mattress. In some embodiments, the mattress 10 is a bunk bed mattress. In some embodiments, the mattress 10 is a futon. In some embodiments, the mattress 10 is a waterbed mattress or air mattress which contains upholstery material between the ticking and the mattress core. In some embodiments, the mattress 10 is 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.

In some embodiments, a method of making the encasement 14 includes one or more of the steps of:

• • Obtaining a mattress core encasement having an upper portion, a lower portion, an open end having an opening, a closed end opposite the open end, a first side extending from the open end to the closed end, and a second side opposite the first side and extending from the open end to the closed end.
  • Cutting a slit in each of the first side and the second side from the open end to a location between the open end to the closed end and by a length. In some embodiments, the length is 10 inches to 20 inches.
  • Folding back a portion of the upper portion onto itself by virtue of the slits to create a fold line.
  • Optionally, stretching the folded back portion of the upper portion onto the upper portion.
  • Cutting an excess portion of the lower portion so that an end of the lower portion is aligned or substantially aligned with the fold line of the upper portion.
  • Sewing the folded portion of the upper portion and the lower portion along the first and second sides to create the opening 28 on the previous open end of the encasement 14 and the flap 30. In some embodiments, the sewing step includes the step of utilizing thread. In some embodiments, the thread is Kevlar thread.

In some embodiments, a method of manufacturing a mattress 10 includes the steps of:

• • Obtaining the encasement 14 as described above;
  • Obtaining the mattress core 12;
  • Inserting the core 12 into the opening 28 of the encasement 14;
  • Pulling the encasement 14 over the core 12 to envelope or substantially envelope the core 12;
  • Pulling the flap 30 of the encasement 14 over the core 12 so that the upper, first portion 24 so that the flap 30 fully covers the first end 44 of the core 12, wherein an underwrap of the encasement 14 is located on the second surface 54 of the core 12.

In some embodiments, the method of manufacturing the mattress 10 does not include sewing, gluing and/or stapling excess material of the encasement 14 around the core 12.

Claims

1. A mattress, comprising: a core; andan encasement, wherein the encasement includes a first end,a second end opposite the first end,a first side,a second side opposite the first side,an upper portion,a lower portion opposite the lower portion,an interior portion,an opening at the first end and in communication with the interior portion, anda flap at the first end, wherein the core is within the interior portion,wherein the flap is moveable from an open position, in which the flap is outside of the opening, and a closed position, in which the flap is within the opening, andwherein the flap overlays at least a portion of the core when the flap is in its closed position.

2. The mattress of claim 1, wherein the core includes a first end, a second end opposite the first end of the core, a first side, a second side opposite the first side, an upper surface, and a lower surface opposite the upper surface, wherein when the flap is in its closed position, the flap covers the first end of the core, at least a portion of the upper surface of the core, and at least a portion of the lower surface of the core.

3. The mattress of claim 2, wherein the core includes first corner edge extending from the upper surface to the lower surface at an intersection of the first end and the first side, and a second corner edge extending from the upper surface to the lower surface at an intersection of the first end and the second side, wherein when the flap is in its closed position, the flap covers the first corner edge and the second corner edge.

4. The mattress of claim 3, wherein the flap includes a first end, a second end opposite the first end of the flap, a first side, a second side opposite the first side of the flap, a first surface extending from the first end of the flap to the second end of the flap and from the first side of the flap to the second side of the flap, and a second surface opposite the first surface of the flap, wherein the first surface of the flap covers the first end of the core when the flap is in its closed position.

5. The mattress of claim 4, wherein a portion of the first surface of the flap is between the upper surface of the core and an interior surface of the lower portion of the encasement.

6. The mattress of claim 4, wherein the first end of the flap is integral with the first end of the encasement.

7. The mattress of claim 5, wherein the second end of the flap is between the first end of the encasement and the second end of the encasement when the flap is in its open position.

8. The mattress of claim 7, wherein the second end of the encasement is closed.

9. The mattress of claim 8, wherein the first side of the flap is aligned with the first side of the encasement when the flap is in its open position, and wherein the second side of the flap is aligned with the second side of the encasement when the flap is in its open position.

10. The mattress of claim 9, wherein the second end of the encasement overlays the second end of the core, wherein the first side of the encasement overlays the first side of the core, wherein the second side of the encasement overlays the second side of the core, wherein the upper portion of the encasement overlays the upper portion of the core, the lower portion of the encasement overlays the lower portion of the core.

11. The mattress of claim 1, wherein the core is composed of foam.

12. The mattress of claim 1, wherein the encasement is composed of a fire retardant fabric.

13. The mattress of claim 1, wherein the opening of the encasement has a height of inches to 20 inches.

14. The mattress of claim 1, wherein the opening of the encasement has a width of inches to 80 inches.

15. The mattress of claim 1, wherein the opening extends from the first side of the encasement to the second side of the encasement and from the upper portion to the lower portion.

16. A method, comprising: obtaining a mattress core encasement having an upper portion, a lower portion, an initial open end, a closed end opposite the open end, a first side extending from the open end to the closed end, and a second side opposite the first side and extending from the open end to the closed end;cutting a slit in each of the first side and the second side from the open end to a location between the open end to the closed end and by a length;folding back a portion of the upper portion onto itself to create a fold line;cutting an excess portion of the lower portion such that an end of the lower portion is substantially aligned with the fold line of the upper portion; andattaching the folded portion of the upper portion and the lower portion along the first side and the second side to create the opening on the initial open end of the encasement and a flap.

17. The method of claim 16, further comprising stretching the folded back portion of the upper portion onto the upper portion prior to the cutting a slit in each of the first side and the second side.

18. The method of claim 16, wherein the step of attaching the folded portion includes sewing.

19. The method of claim 16, wherein the length is 10 inches to 20 inches.

20. A method, comprising: obtaining an encasement having an opening, a flap proximate to the opening, an upper portion, and a lower portion;obtaining a mattress core having a first end, an upper surface, and a lower surface;inserting the mattress core into the opening of the encasement;pulling the encasement over the core;pulling the flap over the core such that the flap fully covers the first end of the core; andinserting at least a portion of the flap between a lower surface of the core and an interior surface of the lower portion of the encasement.