WO2000065964A1

WO2000065964A1 - Mattress cover and method of making same

Info

Publication number: WO2000065964A1
Application number: PCT/CA2000/000477
Authority: WO
Inventors: Simon Zysman
Original assignee: American Risk Management Inc.
Priority date: 1999-05-04
Filing date: 2000-05-03
Publication date: 2000-11-09
Also published as: CA2270708A1

Abstract

A mattress cover (C) comprises mattress top (1) and bottom (2) cover layers, a cover side wall (3) in the form of a band extending around perimeters of the cover layers, the side wall incorporating releasable fastener means (5) extending for a substantial portion of its perimeter intermediate its edges for opening and closing the side wall over the substantial portion of its perimeter, the edges of the side wall being secured one (7) to the peripheral edge of the top cover layer (1) and the other to the peripheral edge of the bottom cover layer (2). Preferably anchoring means (10) for securing the cover to the mattress are provided hidden under the cover side wall. The invention also involves the manufacture of such a cover.

Description

MATTRESS COVER AND METHOD OF MAKING SAME

FIELD OF THE INVENTION

This invention relates to covers for mattresses and, more particularly, to a novel mattress cover into which a mattress can be inserted and the cover then closed without requiring any cover fabrication which cover thereafter can be readily removed.. Further the invention relates to the manufacture of such covers which can be readily produced apart from the mattress to be covered by relatively unskilled workers without requiring the use of the customary tape edge machine.

BACKGROUND OF THE INVENTION

It is conventional practice when covering mattresses to assemble the cover components around the mattress by applying to the mattress top and bottom cover layers. The cover is then permanently closed by a border wall that is secured to the cover layers by means of a binding tape. At least one of the binding tapes has to be applied by a tape edge machine.

The operation of this tape edge machine is both difficult and laborious as the contiguous edges of the cover and the side wall have to be carefully fed into the tape edge machine during the manipulation of the machine or the mattress with the machine being either mounted on a track to move around the mattress or the mattress is moved past the machine. The operation of the tape edge machine requires a very skilled operator and, at the best of times, is a laborious task.

To fix the cover in position against movement on the mattress, under flanges are provided which are secured to the cover layers to lie underneath the cover border flanges. These under flanges are then secured to the springs of the mattress by any suitable means such as hog rings prior to joining the edges of the cover flanges.

The edge of at least one of these under flanges is joined together over the entire perimeter of its respective cover layer in the tape edge machine operation increasing the difficulty of the operation.

It is the object of the present invention to provide a novel cover structure which can be readily produced independently of the mattress to be covered by relatively unskilled workers, the cover being ready for insertion of the mattress and then closed by a releasable closure. It is a further object to provide such a cover which can readily be opened and removed for cleaning, for replacement of the mattress padding, or servicing of the mattress.

SUMMARY OF THE INVENTION

The present invention, in one aspect, resides in providing a mattress cover comprising mattress top and bottom cover layers joined by a separate cover border or side wall extending around the periphery of the top and bottom cover layers, the border or side wall having one edge thereof sewn to one of the cover layers and the other edge thereof sewn to the other cover layer, at least a substantial portion of the perimeter of the border or side wall being openable and closable by a releasable fastener means.

In a preferred embodiment, the border or side wall comprises a pair of strips of cover material connected at one of their edges intermediate the top and bottom cover layers with at least a substantial portion of their connection comprising releasable fastener means, the other edges of said strips being sewn to the respective edges of the top and bottom cover layers.

More particularly, according to the preferred form of the invention, the releasable fastener means comprises a zipper. Further, according to the preferred form of the invention, the cover is provided with at least one under flange fixed at one edge to one of the cover layers beneath the cover border or sidewall, the under flange being adapted for securing the cover to a mattress to be covered to prevent shifting of the cover.

Again, in another aspect, the edges of the border wall, the edges of the cover layers and the respective edge of the under flange are sewn together within a folded bias tape which forms an edging extending around the periphery of the top and bottom cover layers.

In a still further preferred form of the invention, the releasable fastener means is located adjacent one of the cover layers (usually the top layer) and a concealing flap to cover same is secured within the folded edge tape along with the adjacent edges of the cover layer, the border wall, and the under flange to overlie the releasable fastener means.

Again, in another aspect, the invention provides for a novel method of manufacturing mattress covers. In this regard, the mattress cover is produced apart from the mattress itself by providing a top cover layer and a bottom cover layer, forming a separate cover side wall band or border having a substantial portion of its length provided with a releasable fastener means intermediate its edges whereby the cover side wall band or border can be opened and closed over the substantial portion of its length, then securing the edges of the cover side wall, one edge to the edge of the top cover layer, the other edge to the edge of the bottom cover layer.

To provide for the further preferred form of the invention in which the releasable fastener means is concealed, the releasable fastener means is located adjacent to one of the cover layers and a concealing flap is secured to the edge of the said one of the cover layers to overlie the releasable fastener means. Preferably this concealing flap is secured to the respective cover usually the top cover within a folded edge tape simultaneously with the securement of the adjacent edge of the border wall and the under flange.

Preferably a means such as a flange for attachment to the mattress itself for fixing the cover against shifting on the mattress is secured to the edge of one or other or to each of the cover layers beneath the side wall band. Again, preferably the flange, flanges or other cover fixing means are joined to the cover layer or layers simultaneously with the fastening of the edges of the cover side wall to the cover layers.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 is a perspective view of one embodiment of a completed cover in the closed position taken from the rear.

Figure 2 is a perspective view of the the cover of Figure 1 taken from the front.

Figure 3 is a elevational view of a portion of the upper mattress cover layer and the adjacent border wall strip carrying edge of a zipper showing them about to be united along with a securing flange within a folded strip of edge binding tape.

Figure 4 is an enlarged fragmentary view illustrating the binding together of the top cover layer, the top side wall strip and a securing flange.

Figure 5 is a broken away elevational view showing the cover applied to a mattress.

Figure 6 is a broken away perspective view showing the cover secured to the springs of a mattress. Figure 7 is a view similar to Figure 3 but shown in a modified embodiment of the invention in which the upper border wall strip is very narrow and showing the addition of a zipper concealing flap adapted to be assembled with the upper cover, the narrow border strip, and the under flange within a border tape to overlie the zipper teeth.

Figure 8 is an enlarged view showing the elements illustrated in Figure 7 in the assembled state and showing the lower wider border strip about to be joined to the narrow border strip under the zipper concealing flap.

DETAILED DESCRIPTION ACCORDING TO THE PREFERRED EMBODIMENTS OF THE PRESENT INVENTION

With reference to Figures 1 and 2, the mattress cover C of the present invention comprises a top layer or sheet 1, a bottom layer or sheet 2, a border or side wall 3, joined to the top and bottom layers 1 and 2 in an edge binding tape 4 as hereinafter more fully described.

The border or side wall of the cover 3 incorporates a releasable fastening means, preferably a zipper 5, which extends around the major portion of the perimeter of the side wall at a point intermediate the top and bottom cover sheets 1 and 2 leaving only a central portion 6 at the rear of the cover free of the zipper.

It will be understood that as viewed from Figures 1 and 2 the zipper

5 divides the side wall 3 of the cover throughout the length of the zipper into an upper side wall strip 7 and a lower side wall strip 8, it being understood that if the cover were turned over the position of the top and bottom layers and side wall strips would be reversed.

The central portion 6 of the rear of the side wall forms a permanent connection between the top and bottom layers 1 and 2 and, in effect, forms a hinge about which the cover can be opened and closed on the operation of the zipper. In a preferred embodiment of the invention, this side wall hinge portion 6 is simply a continuation of the side wall strips 7 and 8 which are, however, sewn together as indicated at 9 for the length of the hinge 6. It will be understood however that the hinge 6 may be a separate piece of fabric to which the zippered strips 7 and 8 may be attached.

Figure 3 illustrates the method of manufacture of the cover with reference to the securement of the side wall 3 to the top layer 1 and also illustrating the method of attachment of a cover anchoring or securing flange 10 whose function is hereinafter more particularly described.

As illustrated in Figure 3, the top layer 1, the upper side wall strip 7 and the flange 10 are arranged to be brought together within the folded edge or bias tape 4 for stitching. As shown, the lower or distal edge 11 of the side wall strip 7 has attached to it one edge of one of the rows of the interengaging elements or teeth 12. It will be understood that these teeth 12 are adapted to interengage with the teeth 13 of the other edge of the zipper 5 attached to the edge of the side wall strip 8 as shown in Figure 5.

Figure 4 shows the next step in manufacturing the cover illustrating the binding together of the top layer 1 , the top side wall strip 7 and the securing flange 10 within the folded tape 4 by the same stitching 15.

The securing flange 10 may also be stitched to the top layer 1 inwardly of the tape 4 as indicated by stitching 15' so that as this flange is pulled downwardly to be tied into the mattress as hereinafter more fully explained, it will not distort the edge bindings.

It will be understood that the top and bottom layers 1 and 2 and the side wall 3 will be formed from fabric with various designs suitable for enhancing the appearance of the cover. On the other hand, the flange 10 which is hidden beneath the side wall of the cover can be formed from inexpensive fabric material. While Figures 3 and 4 have been described as referring to the uniting of the top layer 1, upper side wall strip 7, and securing flange 10, the bottom layer 2, lower side wall strip 8 will be similarly united to include a securing flange 10.

Preferably at least one of the flanges 10 extends over the length of the cover side wall occupied by the zipper 5.

Figures 5 and 6 show the cover applied to a mattress 16 which is shown as comprising coil springs 17 tied together with springs 18 with suitable border wires 19.

The springs 18 of the mattress are covered with layers of suitable padding or cushioning material 20, the mattress then being ready for the outer covering.

To apply the cover C, the zipper 5 is opened and the top and bottom cover layers 1 and 2 separated at which time the mattress is inserted within the cover.

At this stage, to anchor or fix the cover against movement relative to the mattress, the securing flanges 10 are secured, for example, to the mattress springs 18 by hog rings 21. Once this securement of the mattress is completed the zipper 5 is then closed connecting the border strips 7 and 8 together to complete the covering of the mattress.

While the flanges 10 form a simple means of anchoring the cover in fixed position on the mattress, other anchoring devices such as straps or the like connected within the cover may be used.

If the cover is to be removed as, for instance, for cleaning, replacement of the cushioning material 20 or servicing of the mattress, the zipper 5 is opened allowing the cover side wall to be opened sufficiently to give access to the hog rings which can then be removed and the mattress withdrawn from the cover. The cover may thereafter be reused to cover the mattress as described above and fastened with new hog rings through the flanges 10. The fact that the flanges 10 may have holes therein because of the previous installation of the cover is not material since they are hidden within the side wall 3 on closure of the zipper.

In the embodiment of the invention illustrated in Figures 7 and 8, the releasable fastener means, again preferably the zipper 5, is located close to the top cover sheet or layer 1 giving rise to a very narrow upper side wall strip 7a as compared to strip 7 shown in the previous Figures.2, 5 and 6 and a much wider lower side wall strip 8a, (shown in Figure 8) corresponding to the strip 8 shown in the previous Figures 2, 5 and 6. This narrow strip 7a has one half of the zipper 5 attached to its lower edge so that it teeth 12 are located adjacent the cover sheet 1.

As shown in Figure 7 in addition to the cover sheet 1, the under flange 10 and the side wall strip 7a, there is provided a flap 22 to be included in the folded edge tape 4.

The cover sheet 1, under flange 10, strip 7a and flap 22 are shown assembled in Figure 8 within the folded tape 4 and are held in position as before with stitching 15 with the under flange further held by stitching 15' as previously described.

With the cover sheet or layer 1 under flange 10, side wall strip 7a carrying the zipper teeth 12 and flap 22 assembled as illustrated, this flap 22 hangs down to overlie and hide the zipper teeth 12.

As illustrated in Figure 8, the wider side wall strip 8a carrying the zipper teeth 13 attached to the bottom cover sheet or layer will be fed up between the flap 22 and the under flange 10 as the zipper is closed so that the entire zipper is hidden under the flap 22 while the under flap 22 is completely hidden beneath the side wall formed by the closed side wall strips 7a and 8a. With the flap 22 attached to the top cover sheet 1, it will naturally hand down to cover the zipper 5 so that it may be formed from a suitable flexible fabric material. It will be understood, however, that if the flap 22 were formed from a suitable stiff material, the narrow side wall strip 7a could be attached to the bottom cover sheet 2 and the wider side wall strip 8a attached to the upper corner sheet 1 reversing the arrangement of Figure 8. In this case, the flap 22 would project upwardly because of its stiffness to cover the zipper 5.

It will be understood that the manufacturer of the cover need only know the dimensions of the mattress to be covered. Thereafter the manufacture of the cover is effected by sewing or connecting the various parts together by relatively unskilled workers using, for example, conventional sewing equipment without in any way having to deal with or handle an actual mattress or a tape edge machine.

It will be understood that the variations in the detail of the cover may be made without departing from the scope of the appended claims.

Claims

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:

1. A mattress cover comprising mattress top and bottom cover layers, a cover side wall in the form of a band extending around perimeters of said cover layers, said side wall incorporating releasable fastener means extending for at least a substantial portion of its perimeter intermediate its edges for opening and closing said side wall over said substantial portion of its perimeter, the edges of said side wall being secured one to the peripheral edge of said top cover layer and the other to the peripheral edge of said bottom cover layer.

2. A mattress cover as claimed in Claim 1 further provided with cover anchoring means adapted to be secured to a mattress secured to said cover under said cover side wall.

3. A mattress cover as claimed in Claim 2 in which the edges of said side walls and said cover layers are secured together in a folded edge tape, and said anchor means is secured within one of said folded edge tapes.

4. A mattress cover as claimed in Claims 1, 2 or 3 in which said releasable fastener means is a zipper.

5. A mattress as claimed in Claims 1, 2 or 3 in which said cover side wall comprises a pair of elongated strips of cover material fixedly secured together at one of their edges for a minor portion of their length to form a cover hinge with the remainder of their said one of their edges being connectable by said releasable fastener means.

6. A mattress cover as claimed in Claim 3 in which said anchoring means comprises at least one flange secured at one edge to the edge of one of said cover layers within said folded tape by stitching also securing the said side wall edge to said one cover layer.

7. A mattress cover as claimed in Claim 6 in which said at least one flange is also secured to said one of said cover layers at a point spaced inwardly from its edge.

8. A mattress cover as claimed in Claims 6 or 7 in which said at least one flange extends for the length of said releasable fastener means.

9. A mattress cover as claimed in Claim 8 in which a second flange is secured at one edge to the edge of the other of said cover layers at the point of securement of said cover side wall, said second flange extending at least for the portion of said side wall incorporating said releasable fastener means.

10. A mattress cover as claimed in Claims 1 or 2 in which a flap is attached to one of said cover layers to overlie and conceal said releasable fastener means.

11. A mattress cover as claimed in Claims 1 or 2 in which said releasable fastener means extending for a substantial portion of the perimeter of said side wall is disposed adjacent to one edge of said side wall fastener, and a concealing flap is secured to said one edge of said side wall to overlie said fastener means.

12. A mattress cover comprising mattress top and bottom cover layers, a cover side wall in the form of a band extending around the perimeters of said cover layers, said side wall incorporating releasable fastener means for at least a substantial portion of its perimeter and located adjacent to one edge of said side wall for opening and closing said side wall over said substantial portion of its perimeter, said one edge of said side wall being connected to said top cover layer, the other edge of said side wall being connected to said bottom cover layer, anchoring means adapted to be secured to a mattress secured to said cover under said cover side wall, and a fastener concealing flap secured to said top cover layer to overlie said cover side wall to an extent sufficient to cover said fastener means.

13. A mattress cover as claimed in Claim 12 in which the edges of said side walls and said cover layers are secured together in a folded edge tape, said anchor means comprises at least one flap secured within one of said folded edge tapes, and said fastener concealing flap is secured within the folded edge tape in which said cover top layer and said one edge of said side wall are secured together.

14. A mattress cover as claimed in Claims 12 or 13 in which said side wall is provided with a non-separable hinging section connected between said top and bottom cover layers and dividing said releasable fastener means into two sections one on each side of said hinging section.

15. A method of manufacturing a mattress cover comprising producing a top cover layer and a bottom cover layer, forming a cover side wall in the form of a band for circumscribing the perimeter of said cover layers, forming said band to incorporate a releasable fastening means extending for a major portion of its perimeter and located intermediate of its edges whereby the portion of said band on opposite sides of said releasable fastener means can be separated and reconnected, then attaching the edges of said band to the edges of said cover layers to join said cover side wall to said cover layers.

16. A method as claimed in Claim 15 comprising securing a cover anchor to the edge of at least one of said cover members such that said cover anchor is disposed underneath said cover side wall.

17. A method as claimed in Claim 16 in which said cover anchor comprises a flange secured at one edge to the edge of at least one of said cover members and extending for the length of said releasable fastener means.

18. A method as claimed in Claims 15, 16 or 17 in which said band is formed from a pair of strips of cover material having one of their edges secured together for a minor portion of the perimeter of said sidewall with the remainder of said one of said strip edges carrying zipper interlocking elements and a slider for opening and closing said zipper interlocking elements.

19. A method as claimed in Claims 16 or 17 in which the edges of said cover side wall are attached to the edges of said cover layers and said anchor means by stitching same together within as folded edge tape.

20. A method as claimed in Claims 16 or 17 in which said releasable fastening means is located adjacent one of the edges of said band, and said one edge of said band is attached to said top cover layer, and a fastening means concealing flap to attack to said top cover layer to overlie said fastening means.

21. A method as claimed in Claim 20 in which said top cover layer, the edge of said cover side wall band attached to said top cover, said anchor means and said concealing flap are secured together within folded edge tape.