Note: Descriptions are shown in the official language in which they were submitted.
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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
2 0 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
2 5 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
3 0 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
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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
2 0 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
3 o 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.
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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
2 0 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
2 5 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
3 0 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.
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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
1 o 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
3 0 applied to a mattress.
Figure 6 is a broken away perspective view showing the cover
secured to the springs of a mattress.
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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
2 0 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.
2 5 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.
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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.
2 5 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.
3 0 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.
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While Figures 3 and 4 have been described as referring to the
uniting of the top layer l, 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
2 0 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
2 5 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
3 0 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
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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
2 0 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
2 5 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
3 o 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
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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,
1o 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.
2 0 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.
