Abstract:
A mattress ( 22 ) having a foam core ( 8 ) completely extends to the perimeter edges of the mattress wherein side walls ( 15 ) of the foam core are compressed inward and held in place using a preferably non-woven strip of fabric ( 21 ) or similar non-elastic or non-stretchable material that is wrapped around the side walls of the foam core. A method of wrapping the foam core allows corners ( 5 ) of the foam core to be formed under the inward pressure of the non-woven fabric, thereby creating a strong perimeter for the mattress that prevents outward pressure against the sidewalls created by the downward pressure of an individual lying on the mattress from flattening of the mattress by providing more upward pushback against the individual. An optional layer of micro-coil springs ( 2   a ) may be located within the foam core to provide more buoyancy and springiness in the mattress.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of U.S. Provisional Patent Application No. 61/559,994, filed Nov. 15, 2011. The patent application identified above is incorporated herein by reference in its entirety to provide continuity of disclosure. 
    
    
     FIELD OF THE INVENTION 
     This invention relates to mattresses, more particularly, a mattress constructed of foam which extends all of the way to the outer perimeter edge of the mattress and is wrapped with a non-elastic or a non-stretchable material, such as a non-woven cloth, and an optional layer of micro-coil springs to provide more buoyancy and springiness in the mattress. 
     BACKGROUND OF THE INVENTION 
     Foam mattresses are designed for pressure management. When an individual lies on a foam mattress, the foam should distribute the individual&#39;s body weight evenly across the entire sleeping surface to reduce uncomfortable pressure points. Foam mattresses are typically constructed using multiple layers of foam. Some foam mattresses are constructed out of latex foam, Talalay latex foam, Dunlop latex foam, memory foam and so forth. Many foam mattresses traditionally require a foam encasement comprising foam panels that create a frame around the core of the mattress. There are three common reasons conventional mattresses are made with a foam encasement. The first is to shape the corners of the mattress. The second is to provide lateral support to the mattress core to prevent the mattress core from spreading under the weight of an individual and failing to provide proper support. The third is to provide a sitting edge on the mattress that is sturdy enough to hold an individual sitting on the edge of the mattress. 
     However, such conventional foam encasements are typically two to four inches wide and are constructed out of a polyurethane foam having a density greater than that of the typically latex foam core, thereby creating a dense uncomfortable ridge around the perimeter edge of the mattress. In addition, polyurethane foam commonly breaks down over time, thereby becoming softer and failing to provide a sturdy sitting edge. An even further problem with foam encasements is that the foam is flexible, thereby allowing the foam core to spread under a user&#39;s weight, thereby flattening the mattress. 
     Therefore, a need exists for a mattress constructed using a method that eliminates the need for conventional foam encasements, provides equal edge-to-edge comfort across the entire mattress, allows the sides and corners of the mattress to be properly shaped and ensures the mattress retains its shape during use, thereby providing long lasting comfort. 
     The relevant prior art includes the following references: 
     
       
         
               
               
               
               
             
               
             
               
               
               
               
             
           
               
                   
                   
               
               
                   
                 Patent No. 
                 Inventor 
                 Issue/Publication Date 
               
               
                   
                   
               
             
             
               
                   
               
             
          
           
               
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                 Wagner et al. 
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                 Boyd 
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                 Sabalaskey et al. 
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                 O&#39;Connell et al. 
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                 2011/0191962 
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                 Aug. 11, 2011 
               
               
                   
                   
               
             
          
         
       
     
     SUMMARY OF THE INVENTION 
     The primary object of the present invention is to provide a mattress constructed using a method and system that eliminates the need for conventional foam encasements. 
     An additional object of the present invention is to provide a mattress constructed using a method and system that provides equal edge-to-edge comfort across the entire mattress. 
     A further object of the present invention is to provide a mattress constructed using a method and system that allows the edges and corners of the mattress to be properly shaped. 
     An even further object of the present invention is to provide a mattress constructed using a method and system that prevents flattening of the core and ensures the mattress retains its shape during use, thereby providing long lasting comfort. 
     The present invention fulfills the above and other objects by providing a mattress constructed using a method wherein a foam core completely extends to the perimeter edges of the mattress. The side walls of the foam core are compressed inward and held in place using a preferably non-woven fabric or similar non-elastic or non-stretchable material that is wrapped around the side walls of the foam core. The method of wrapping the foam core allows the corners of the mattress to be formed under the inward pressure of the non-woven fabric on the side walls of the foam core. Further, the preferably non-woven fabric has no elasticity. This creates a strong perimeter for the mattress that prevents outward pressure against the sidewalls created by the downward pressure of an individual lying on the mattress, thereby preventing flattening of the mattress by providing more upward pushback against the individual. The flattening of the mattress is prevented whether the user is lying on the center of the mattress or sitting on the edge of the mattress. An additional benefit of the method of the present invention is that the non-woven fabric encases staples used to secure flanges of the cover to the side walls of the foam core, thereby preventing the staples from pulling out of the foam core. This is especially important due to the fact that many foam mattresses are used in adjustable beds wherein the mattresses are bent up and down, thereby making such a staple failure more likely. 
     The above and other objects, features and advantages of the present invention should become even more readily apparent to those skilled in the art upon a reading of the following detailed description in conjunction with the drawings wherein there is shown and described illustrative embodiments of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In the following detailed description, reference will be made to the attached drawings in which: 
         FIG. 1  is a perspective top partial cutaway view of a conventional foam mattress; 
         FIG. 2A  is a top perspective view of a foam core of a mattress of the present invention; 
         FIG. 2B  is a top perspective view of a foam core of a mattress of the present invention having a layer of micro-coil springs; 
         FIG. 3  is an exploded top perspective view of a foam core of the present invention and a bottom cover of the mattress of the present invention; 
         FIG. 4  is a partially exploded top perspective view of a foam core of the present invention already placed in a bottom cover and a top cover of the mattress of the present invention; 
         FIG. 5  is a top perspective view of the flanges of the top cover and the flanges of the bottom cover secured to the side walls using staples; 
         FIG. 6  is a front view of a flair staple; 
         FIG. 7  is a partially exploded top perspective view of a non-woven strip of fabric and mattress of the present invention; 
         FIG. 8  is a top perspective view of a foam core wrapped in a non-woven strip of fabric of the present invention; 
         FIG. 9  is a top perspective view of a mattress of the present invention having the side panels of the top cover folded and sewn to the bottom panel; 
         FIG. 10  is a partially exploded top perspective view of a non-woven strip of fabric and foam core of the present invention; and 
         FIG. 11  is a foam core wrapped in non-woven fabric. 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     For purposes of describing the preferred embodiment, the terminology used in reference to the numbered accessories in the drawings is as follows:
           1 . conventional foam mattress     2 . foam core     3 . layer of foam     4 . edge of foam core     5 . corner of foam core     6 . foam encasement     7 . foam panel     8 . foam core     9   a . layer of foam     9   b . micro-coil spring layer     10 . edge of foam core     11 . corner of foam core     12 . bottom cover     13 . bottom flange     14 . perimeter of bottom cover     15 . side wall of foam core     16 . top cover     17 . upper surface of foam core     18 . top flange     19 . perimeter of top cover     20 . staple     21 . non-woven strip of fabric     22 . mattress     23 . outer surface of top flange     24 . adhesive     25 . first end of non-woven strip of fabric     26 . second end of non-woven strip of fabric     27 . side cover panels       

     With reference to  FIG. 1 , a perspective top partial cutaway view of a conventional foam mattress is illustrated. The conventional foam mattress  1  comprises a foam core  2  made up of various layers of foam  3 , preferably latex foam, to create the main body of the mattress  1 . The various layers of foam  3  are made up of foams having different densities and qualities. The thickness, firmness and overall quality of the mattress  1  is controlled by layering the different foams throughout the core  2 . However, by layering the foam  3 , the foam core  2  is left with uneven edges  4  and corners  5 . Therefore, the core  2  is surrounded and framed by a foam encasement  6  that is constructed out of foam panels  7  having a height equal to that of the core. By using a foam encasement  6 , the edges  4  of the foam core  2  are straight and the corners  5  are rounded correctly. However, there are many disadvantages of using conventional foam encasements  6  which are discussed above in the background section. 
     With reference to  FIG. 2A , a top perspective view of a foam core  8  of a mattress the present invention is illustrated. The foam core  8  is made up of various layers of foam  9   a , preferably latex foam, thereby leaving uneven edges  10  and corners  11 . Although the method described herein is used with a layered foam core  8 , the method may also be used with a solid foam core to provide correctly shaped corners and a solid perimeter edge and to prevent uneven displacement and spreading of the solid foam core. 
     With reference to  FIG. 2B , a top perspective view of a foam core  8  of a mattress of the present invention having a layer of micro-coil springs  9   b  is illustrated. One or more layers of micro-coil springs  9   b  may be located between any of the layers of foam  9   a  to provide more buoyancy and springiness in the foam core  8 . However, at least one layer of micro-coil springs  9   b  is preferably placed proximate to an upper surface  17  of the foam core  8  to provide the maximum benefit. The one or more micro-coil spring layers  9   b  may also be placed in a central location within the foam core  8  and framed by a layer of foam  9   a  on the edges of the foam core  8  to provide a denser edge to the mattress. The method of wrapping a foam core  8  described herein may also be used on a foam core  8  having one or more micro-coil spring layers  9   b  to provide correctly shaped corners  11  and a solid perimeter edge and to prevent uneven displacement and spreading of the foam core  8 . 
     With reference to  FIG. 3 , an exploded top perspective view of a foam core  8  of the present invention and a bottom cover  12  of the mattress of the present invention is illustrated. The foam core  8  is placed on top of the bottom cover  12 . Then, bottom flanges  13  extending upward from the perimeter  14  of the bottom cover  12  are pulled up around side walls  15  of the foam core  8 . 
     With reference to  FIG. 4 , a partially exploded top perspective view of a foam core  8  of the present invention already placed on a bottom cover  12  and a top cover  16  of the mattress of the present invention is illustrated. After the foam core  8  is place on top of the bottom cover  12  and the bottom flanges  13  of the bottom cover  12  are pulled up around the side walls  15  of the foam core  8 , the top cover  16  is placed over an upper surface  17  of the foam core  8  and top flanges  18  extending downward from the perimeter  19  of the top cover  16  are pulled down and around the side walls  15  of the foam core  8  and the bottom flanges  13 . The bottom flanges  13  and top flanges  18  are preferably a fabric material. Then, the top flanges  18  and the bottom flanges  13  are secured to the side walls  15  by stapling through the flanges  13 ,  18  into the side walls  15 , preferably using flair staples  20  that spread apart after entering the foam core  8 , as illustrated in  FIGS. 5 and 6 , respectively. 
     With reference to  FIG. 7 , a partially exploded top perspective view of a non-woven strip of fabric  21  and mattress  22  of the present invention is illustrated. After the flanges  13  and  18  are secured to the side walls  15  of the foam core  8 , a non-woven strip of fabric  21  or other non-flexible non-stretchable material is secured the outer surface  23  of the top flange  18  using an adhesive  24 , such as a water based glue, which may be sprayed on the outer surface  23  of the top flange  18  (or the an outer surface of the bottom flange if the bottom flange is covering the top flange). A first end  25  of the non-woven strip of fabric  21  is then secured to the top flange  18  and wrapped around the side walls  15  of the foam core  8 . As the non-woven strip of fabric  21  is wrapped around the foam core  8 , the non-woven strip of fabric  21  may be pulled with varying degrees of force to apply the proper amount of tension and inward pressure on the side walls  15  of the foam core  8  to create straight side walls  15  and properly formed corners  11 . Then, a second end  26  of the non-woven strip of fabric  21  is secured to the top flange  18  using the adhesive  24 . The non-woven strip of fabric  21  may then be smoothed out. Finally, side cover panels  27  extending from the top cover  16  may be folded down over the non-woven strip of fabric  21  and sewn to the perimeter  14  of the bottom cover  12 , thereby completely encapsulating the foam core  8 , flanges  13 ,  18  and non-woven strip of fabric  21  in the top cover  16 , sided cove panels  27  and the bottom cover  12 , as illustrated in  FIGS. 8 and 9 , respectively. 
     With reference to  FIG. 10 , a partially exploded top perspective view of a non-woven strip of fabric  21  and foam core  8  of the present invention is illustrated. The method of the present invention may also be used with other mattress covers, such as sock mattress covers, wherein the foam core  8  is directly wrapped with a non-woven strip of fabric  21  or other non-flexible non-stretchable material using an adhesive  24 , such as a water based glue, which is sprayed directly on the side walls  15  of the foam core  8 . A first end  25  of the non-woven strip of fabric  21  is then secured to the side walls  15  and wrapped around the side walls  15  of the foam core  8 . As the non-woven strip of fabric  21  is wrapped around the foam core  8 , the non-woven strip of fabric  21  may be pulled with varying degrees of force to apply the proper amount of tension and inward pressure on the side walls  15  of the foam core  8  to create straight side walls  15  and properly formed corners  11 . Then, a second end  26  of the non-woven strip of fabric  21  is secured using the adhesive  24 . The non-woven strip of fabric  21  may then be smoothed out. After the non-woven strip of fabric  21  has been smoothed out, as illustrated in  FIG. 11 , a cover, such as a sock cover, may be used to cover the wrapped foam core  8 . 
     It is to be understood that while a preferred embodiment of the invention is illustrated, it is not to be limited to the specific form or arrangement of parts herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is shown and described in the specification and drawings.