Patent Publication Number: US-2017347814-A1

Title: Knitted Mattress Cover, Mattress and Method for Manufacturing a Knitted Mattress Cover

Description:
BACKGROUND OF THE INVENTION 
     Field of the Invention 
     The present invention relates to a mattress cover, and more in particular a knitted mattress cover. The invention further relates to mattress comprising such a mattress cover and a method for manufacturing a knitted mattress cover according to the invention. 
     Description of Related Art 
     Commonly known mattress covers are composed of plurality of components such as panels, borders, gussets and tape edges. During the manufacturing of such mattress covers, these components need to be cut to their required size and need to undergo several sewing operations for the hemming of the edges. Moreover, additional sewing operations are needed to join these individual components together to form the finished mattress cover. All of the above manufacturing steps are labour intensive and often require additional, costly equipment. Moreover, to meet certain market demands, mattress covers are commonly provided with additional product features that change the shape and appearance of these covers and therewith the mattress that they encase. Additional manufacturing steps and labour are hereby necessary to incorporate these features into the mattress covers. 
     It is therefore an object of the invention to provide a mattress cover that allows for a simplified production process and therefore an increase in production rate and a decrease in production costs. A further object of the invention is to provide a mattress cover that allows for easy incorporation of additional product features. 
     SUMMARY OF THE INVENTION 
     The invention thereto proposes a knitted mattress cover comprising: a top panel, at least one side panel, and at least one tape edge connecting the top panel with the at least one side panel, wherein the top panel, the at least one side panel and the at least one tape edge are integrated into a seamless, one-piece knit. An advantage of such a mattress cover (also known as a ticking) wherein all components that make up the mattress cover are incorporated into a one-piece knit, is that intensive labour requirements are obviated as no additional cutting or sewing steps are necessary. This brings down both production costs and production time. 
     In an embodiment of a knitted mattress cover according to the invention, the at least one side panel is at a free edge thereof provided with at least one gusset, wherein the gusset is knitted onto the mattress cover to form part of the one-piece knit. Gussets may be added to the side panel or border of the mattress to create more cushioning and to strengthen the corners of the mattress cover that may act as connection zones for other panels, and specifically the bottom panel of the mattress cover. 
     In another embodiment of a knitted mattress cover according to the invention, the tape edge is kept in a lengthwise folded position by means of a single stitch. Folding and stitching of the tape edge creates an raised edge that separates the top panel and the one or more side panels which otherwise would lay flat against the mattress. Additionally the lengthwise folded tape edge encloses a cord to increase the strength and firmness of the raised edge. 
     In yet another embodiment of a knitted mattress cover according to the invention, the tape edge follows a curved line across the side of the mattress, thereby creating a curved blister transition between the top panel and the side panel(s) or borders of the mattress cover. This construction creates an optical effect where it seems that the borders of the mattress vary in height over the length of the border. 
     It is also possible that the mattress cover comprises a knitted design element, more specifically a pattern and/or a logo, which forms an integral part of the mattress cover. Patterns commonly used on mattresses are patterns that give the mattress or parts thereof a quilted look. As the patterns is an integral part of the mattress cover, an appearance is achieved that is (nearly) identical to traditionally quilted covers without the necessity of performing an extra production step involving a quilting machine. A similar reduction in labour costs may be achieved with the incorporation of labels (e.g. to depict company logo&#39;s or emblems) that are directly knitted into the cover fabric and form an integral part of the mattress cover over the incorporation of labels that are for example sewn in or embroidered into the cover fabric. 
     The invention also relates to a mattress comprising a core having a top and at least one side, which top and at least one side are least partly encased by a knitted mattress cover according to the invention. In an embodiment of the mattress, the mattress cover fully encloses the top and sides of the core. Herewith a full wrap cover is created that at least encloses the top and sides of the mattress and eliminates the need for additional top or side panels to be sewn or otherwise connected to the mattress cover. In addition, it is possible that the mattress comprises a bottom side covered by a non-woven fabric. The non-woven fabric hereby forms a durable, cost-effective and lightweight backing material. 
     The invention further relates to a method for manufacturing a knitted mattress cover comprising integrally knitting a top panel, at least one side panel and at least one tape edge to form a one-piece cover. With this method, the several component that make up the mattress cover are manufactured and integrated into a one-piece cover with a single knitting operation. This significantly simplifies the process for manufacturing a mattress cover compared to commonly used processes, thus increasing production rates and decreasing production (labour) costs. Moreover, the fact that the mattress cover is knitted provides the mattress cover an inherent elasticity that allows the same cover to fit around mattresses of different sizes by means of stretching the cover in more or lesser degree. Another advantage of knitting a one-piece cover is the possibilities this method of manufacturing creates for the incorporation of all sorts of constructional features, such as the application of a curved tape edge. Where such construction with commonly used manufacturing methods of cutting and sewing are close to impossible to create due to high labour costs of sewing such curved tape edge, incorporating a curved tape edge in a one-piece knit is only a matter of programming the knitting machine with the desired pattern. 
     It is possible that the method for manufacturing a knitted mattress cover according to the invention involves folding the at least one tape edge and consecutively stitching the tape edge in its lengthwise direction after knitting. This method creates an raised edge in the end product that separates the top panel and the one or more side panels which would otherwise lay flat against the mattress. In addition, it is possible that the method involves a cord being inserted between the fold of the tape edge to create a raised edge of increased strength and firmness. 
     It is further possible that during knitting a design element, more specifically a pattern and/or a logo, is knitted into the face fabric of the mattress cover. Direct integration of design elements in the mattress cover eliminate otherwise performed manufacturing steps including sewing, embroidering and quilting. 
     In addition, it is possible that the mattress cover is knit in a direction corresponding to a lengthwise direction of the mattress cover. The maximum dimension of a knitted mattress cover is generally dependent on the width of the knitting machine on which the cover is knitted. By knitting in a direction corresponding to a lengthwise direction of the mattress cover, only the width of the mattress cover and the thereto connected side panel(s) and/or gusset(s) are limited by the length of the knitting machine. This allows for a maximization of the dimensions of the mattress cover, eliminating the need for separate foot- and/or headboards that need to be connected (separately stitched) to the cover. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In order to further elucidate the invention, exemplary, non-limitative embodiments will be described with reference to the figures. In the figures: 
         FIG. 1  shows a plan view of a knitted mattress cover according to an embodiment of the invention, 
         FIG. 2  shows a plan view of another knitted mattress cover according to an embodiment of the invention, 
         FIG. 3  shows a perspective view of a mattress comprising a mattress cover according to the invention, and 
         FIG. 4  shows a detail of a mattress comprising a mattress cover according to the invention. 
     
    
    
     The figures represent specific exemplary embodiments of the invention and should not be considered limiting the invention in any way or form. Throughout the description and the figures corresponding reference numerals are used for corresponding elements. 
     DESCRIPTION OF THE INVENTION 
       FIG. 1  depicts a plan view of a knitted mattress cover  1  according to an embodiment of the invention. The mattress cover, also known as the ticking, comprises a top panel  2  and multiple side panels  3 . A tape edge  4  connects the top panel  2  with each of the side panels  3 . The side panels are at a free end thereof provided with gussets  5 . The mattress cover  1  could amongst others comprises a cotton or a linen textile. The top panel  2  and/or the side panels  3  may be provided with patterning or a logo  6 , which pattern or logo  6  is directly knitted into the fabric of the mattress cover  1 . The mattress cover as shown in  FIG. 1  is able to fully enclose the top and sides of a mattress. However, it is also possible that the mattress cover encloses only part of the mattress, wherein additional panels are provided to connect with the mattress and cover the complete mattress core. 
       FIG. 2  shows another plan view of a knitted mattress cover  1  according to an embodiment of the invention. A difference with the mattress cover  1  depicted in  FIG. 1  is the placement and shape of the tape edge  4  following a curved line across the side of the mattress  3 . 
       FIG. 3  shows a perspective view of a mattress  7  comprising a mattress cover  1  according to the invention. The mattress is encased by the mattress cover  1 , comprising a top panel  2 , side panels  3  and a tape edge  4  and placed on a bedframe  8 . The side panels  3 , constituting the border of the mattress  7 , are provided with a pattern  9  that gives the cover a quilted look. 
       FIG. 4  shows a detail of a mattress  7  comprising a mattress cover  1  according to the invention. The mattress cover  1  comprises a folded tape edge  4  that is kept in place by a stitched seam  10 . The tape edge  4  could enclose a cord or rope (not shown) to give the tape edge additional rigidity. Again, the side panels  3  are provided with patterning  9 .