US20240398127A1

US20240398127A1 - Mattress assembly with mattress cover and method for transporting and assembling a mattress

Info

Publication number: US20240398127A1
Application number: US18/327,542
Authority: US
Inventors: Giacomo Dell'Accio
Original assignee: Kythos LLC
Current assignee: Kythos LLC
Priority date: 2023-06-01
Filing date: 2023-06-01
Publication date: 2024-12-05

Abstract

A mattress assembly includes a first rollable core with an engagement side and a base side. A first cover has a first cover internal panel, the first cover receives the first rollable core therein with the first cover internal panel against the engagement side. The first cover has a first part of an attachment fastener extends along the first cover internal panel. The assembly has second rollable core with a second core base side and a sleep side. A second cover has a second cover internal panel, the second cover receives the second rollable core therein with the second cover internal panel against the second core base side. The second cover has a second part of the attachment fastener to mate with the first part and orient the internal panels against one another with the base side and the sleep side disposed externally. The second part extends along the second cover internal panel.

Description

BACKGROUND OF THE INVENTION

Field of the Invention

The invention relates, generally, to a mattress assembly with a mattress cover and a method of transporting and assembling a mattress using the mattress cover assembly.
Mattress covers are used to protect the surfaces of mattresses from soiling and are removable for the purposes of cleaning the cover in the wash. Mattresses are often times transported in a rolled up and compressed (vacuum packed) state via common home delivery carriers. The carriers have weight and size limits for their standard service. The weight limit is 149 pounds fully packaged weight. Online mattress brands that ship via the common carriers have low density mattresses the fall below the weight limit. Foam mattresses may have foams with higher foam densities or other constructions of materials with higher densities and the weight limit of the common carriers results in a limit on the thickness of a mattress especially in the larger mattress size formats. Typically, high density foam mattresses are limited to a thickness of about 8″ due to the weight limit, while other compressed mattress that are not high density are of a 12-14″ profile.

Description of the Related Art

US Patent Application Publication No. 2007/0067916 to Poston discloses mattress encasings and apparatuses to encase a mattress topper. The mattress encasing is constructed with a zipper half at a top edge of the mattress encasing. The topper encasing has a mating zipper half that attaches to the mattress encasing zipper to connect the two encasings. The zipper allows access to the two components inserted between the encasings. The encasings do not provide for a proper assembly of components within the assembled encasings. The reference does not consider densities of the components within the encasings and the transport and proper assembly thereof.
U.S. Pat. No. 9,955,796 to Schulte discloses a mattress protector and removable cover assembly. Schulte discloses a mattress that has protector that covers the mattress. The cover has a zipper portion that mates with a zipper portion at the sides of the protector. The cover may include a pocket for a topper. The reference does not consider densities of the components within the protector and the cover and the transport and proper assembly thereof.
WO 2017/004618 to Scarleski discloses a chiral zipper system provided on mattress layers to allow flipping and or rotation of the comfort top and bottom support layer relative to one another. The reference does not consider densities of the comfort top and bottom support layer and the transport and proper assembly thereof.
In applicant's prior experience, in shipping and delivering multi-part mattress assemblies, the issues that were seen even with what were believed to be detailed instructions, many consumers or the person assembling the mattress ware either ignoring or not correctly following the directions. They would frequently stack the layers in the incorrect order or position the internal layers reversed.

SUMMARY OF THE INVENTION

It is accordingly an object of the invention to provide a mattress assembly with mattress covers that overcomes the herein-mentioned disadvantages of the heretofore-known devices of this general type, which is able to ensure proper assembly after transport to a consumer and a method for transporting mattress of high weight by the common shipping carriers. Particularly, the invention provides for achieving greater thicknesses for high density foam mattresses that are shipped by the common carriers.
With the foregoing and other objects in view there is provided, in accordance with the invention, a mattress assembly that includes a first rollable core with an engagement side and a base side. A first cover has a first cover internal panel, the first cover receives the first rollable core therein with the first cover internal panel against the engagement side. The first cover has a first part of an attachment fastener extends along the first cover internal panel. The assembly has second rollable core with a second core base side and a sleep side. A second cover has a second cover internal panel, the second cover receives the second rollable core therein with the second cover internal panel against the second core base side. The second cover has a second part of the attachment fastener to mate with the first part and orient the internal panels against one another with the base side and the sleep side disposed externally. The second part extends along the second cover internal panel.
This construction allows to insert the layers at the factory and completely removes the possibility of errors in assembly. This while continuing to provide a cover that is removable for washing.
In accordance with another feature of the invention, the first and second covers each have a respective openable fastener to allow for insertion of the respective cores.
In accordance with another feature of the invention, the openable fasteners are zippers disposed to extend along the internal panels.
In accordance with another feature of the invention, the zippers are behind the attachment fastener when the attachment fastener parts are mated with one another.
In accordance with another feature of the invention, the cores are each formed of high-density materials.
In accordance with another feature of the invention, the cores are each formed of multiple different layers of high-density latex.
In accordance with another feature of the invention, the cores combined have a weight of greater than 145 pounds.
In accordance with yet another feature of the invention, at least one of the internal panels is an anti-slip material.
In accordance with still yet another feature of the invention, the attachment fastener is a zipper and the parts of the attachment fastener are respective zipper teeth sets.
Additionally, there is provided, in accordance with the invention a method of of delivering and assembling a mattress assembly that provides a mattress assembly that is constructed of two rollable cores that have a combined weight of greater than 145 pounds with each of the cores less than 145 pounds. Each of the cores have a respective internal side that rest against one another when the cores are assembled to one another. To provide each of the cores with a respective mattress cover that each have a respective attachment fastener part that extends along the periphery of the internal surfaces. Individually rolling up, packaging and shipping the cores with the covers to an end user. To stack the cores with the internal sides rested against one another. To connect the attachment fastener parts to one another to complete the mattress assembly.
In accordance with another feature of the invention, the cores are each formed of high-density material.
In accordance with another feature of the invention, the high-density material is multiple layers of latex foam.
Other characteristic features of the invention are set forth in the appended claims.
Although the invention is illustrated and described herein as embodied in mattress assembly with a mattress cover, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
The construction of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is a perspective view of a mattress assembly according to the invention;

FIG. 2 is a side view of the mattress assembly;

FIG. 3 shows a perspective view of a first mattress cover of the mattress assembly;

FIG. 4 shows a perspective view of a second mattress cover of the mattress assembly;

FIG. 5 is an enlarged perspective view of the mattress assembly with the cores pulled apart and the covers partially opened;

FIG. 6 is a schematic section view of layers of cores of the assembly; and

FIG. 7 is another schematic section view of layers of cores of the assembly.

DETAILED DESCRIPTION OF THE INVENTION

In all the figures of the drawing, sub-features and integral parts that correspond to one another bear the same reference symbol in each case.
FIG. 1 shows a perspective view of a mattress assembly 1 that has a base core 10 and topper core 20. The base core 10 is constructed for placement on a support surface (frame with slats, floor, or other foundation) with a base side 11. The base core 10 has an engagement side 12 that supports the topper core 20 thereon. The topper core 20 has a base side 21 that is constructed to rest upon the engagement side 12 of the base core 10. The topper core 20 has a sleep side 22 for the user to sleep or rest upon. The cores are constructed of various layers L of high-density foam, where high density is considered to be greater than 2.5 lbs/ft³. The layers L may be latex foam.
The cores 10 and 20 are constructed to be rollable. Rollable in the context of the invention requires that the cores are able to be rolled-up and compressed then unrolled to again assume a flat state (same as prior to rolling-up) suitable for a mattress. The cores are rolled-up and packaged for shipping and are then able to be unwound from the rolled-up state for final use by an end consumer. The cores are rolled-up in preparation for placement into an outer packaging for shipment to the end user. Upon arrival the rollable cores are unpacked, unwound and return to a flat planar state suitable for a mattress.
The base core 10 is provided with a base core cover 13 that has a base core cover openable fastener 14, such as a zipper to provide for insertion of the base core 10 into the base core cover 13 and the closing of the base core cover 13 to enclose the base core 10 therein as is seen in FIG. 5. The openable fastener 14 may be provided along an edge of the side panels 15 of the base core cover 13 and has a length or extent sufficient to allow for insertion, placement, and removal of the base core 10 from the base core cover 13 when the openable fastener 14 is in an open state. The base core cover 13 is provided with an internal panel 16 (internal referring that the panel 16 is internal to the stack in the stacked assembly of the cores) that is disposed on the engagement side 12 of the base core 10 when the cover 13 is on the base core 10. The side panels 15 extend from the four sides of the internal panel 16. The base core cover 13 is provided with a first part 17 of an assembly fastener, such as one side of zipper teeth. The first part 17 of the assembly fastener may be provided at the side panels 15 of the base core cover 13, so as to extend along the edge of the engagement side 12 of the base core 10 when the base core 10 is inserted in the base core cover 13 with the cover 13 in a closed state.
The topper core 20 is provided with a topper core cover 23 that has a topper core cover openable fastener 24, such as a zipper to provide for insertion of the topper core 20 into the topper core cover 23 and the closing of the base core cover 23 to enclose the topper core 20 therein as is seen in FIG. 5 . The openable fastener 24 may be provided along an edge of the side panels 25 of the topper core cover 23 and has a length or extent sufficient to allow for insertion, placement, and removal of the topper core 20 from the topper core cover 23 when in an open position. The topper core cover 23 is provided with an internal panel 26 that is disposed on the base side 21 of the topper core 20 when the cover 23 is on the topper core 20 and which mates against the internal panel 16 of the base core cover 13 in in an assembled state of the cores. The side panels 25 extend from the four sides of the internal panel 26. The topper core cover 23 is provided with a second part 27 of the assembly fastener, such as a mating side of zipper teeth to those on the base core cover 13. The second part 27 of the assembly fastener may be provided at the side panels 25 of the topper core cover 23 so as to extend along the edge of the base side 21 of the topper core 20 when the topper core 20 is inserted in the topper core cover 23 with the cover 23 in a closed state.
It is seen from FIG. 5 that the openable fasteners 14 and 24 may be disposed at a position that is behind the assembly fastener when the two parts 17 and 27 of the assembly fastener are in a mated and assembled position. Instead of zippers it is possible for the fasteners to be provided as mating snap elements, hook and loop elements or any other type of fasteners that can be repeatedly engaged and disengaged. The position of the openable fasteners 14 and 24 can be on the respective side panels between the edge of the mating sides and the two parts 17 and 27 of the assembly fastener. This feature hides the two openable fasteners 14 and 24 from view when the assembly fastener is closed and the cores 10 and 20 are assembled. The internal panels 16 and 26 may be an anti-slip material to help prevent shifting of the stacked cores and reduce stress on the assembly fastener due to forces generated by users on the mattress assembly. The side panels 15 and 25 may be of a finishing fabric that has a color and/or pattern distinction for the respective core to make identification for the appropriate core direct and straightforward.
As is seen in FIGS. 6 and 7 , the respective cores 10 and 20 may be constructed of various layers BL and TL of latex material. Each of the layers is disposed relative to one another to define the characteristics of the mattress. Thus, the assembled orientation of the cores 10 and 20 is critical for the desired performance of the mattress. As seen in the Figures. the layers may have different densities or other structural characteristics that make the layer suitable for its position in the stack of layers. As shown in FIGS. 6 and 7 , the topper core 20 may have one or two layers TL1 and TL2, however more layers are possible. As shown in FIG. 6 , the base core 10 may have three layers BL1-BL3 and FIG. 7 shows 4 layers BL1-BL4 for the base core however more or fewer layers are possible. The orientation of the layers in the cores and the disposition relative to one another is what is important for the mattress assembly to perform as desired and what the assembly 1 ensures will result when assembled by the user.
The mattress assembly 1 provides for a method of transporting a mattress with packaging by common carriers that exceeds the allowable weight of 149 pounds for standard service, while ensuring proper assembly at the end user. The method includes providing a mattress that exceeds 149 pounds with packaging and dividing the mattress into separate cores which are individually less than 149 pounds. The cores being a topper core 20 and a base core 10. The topper core 20 is placed into the topper core cover 23 in the correct orientation of the core 20, with the base side 21 placed against the internal surface 26 of the cover 23 and the cover 23 is closed. This results in the proper orientation of the part 27 of the attachment fastener relative to the topper core 20 for attachment to the base core cover 13. The topper core 20 with cover 23 is then rolled and compressed and packaged for shipment. The base core 10 is placed into the base core cover 13 in the correct orientation of the base core 10, with the engagement side 12 placed against the internal surface 16 of the cover 13 and the cover 13 is closed. This results in the proper orientation of the part 17 of the attachment fastener relative to the topper core 20 for attachment to the topper core cover 23. The base core 10 with cover 13 is then rolled and compressed and packaged for shipment. The cores are shipped to the end user by a common carrier. Upon receipt, the respective cores are removed from the packaging and the base core 10 is placed in the desired location with the base side 11 on the supporting surface for the mattress. The topper core 20 is placed on the base core 10 with the base side 21 on the engagement side 12 so that the internal surfaces 16 and 26 rest against one another and then the parts 17 and 27 of the attachment fasteners are connected to one another. The orientation of the attachment fastener parts ensures that the cores 10 and 20 are in the proper orientation with the layers of the cores in the correct relationship for proper functionality of the mattress.
This construction can also provide for upgrades of a mattress if an advancement is made in one of the cores 10, 20. This is done by supplying a new core in which an advancement/improvement has been made and allows for a more cost effective upgrade of a mattress than purchasing an entire assembly. The assembly 1 also provides for addressing damage or warranty issues by allowing for replacement of a core that may be defective or damaged, while the remaining undamaged core is able to be maintained at the user's location.

Claims

1. A mattress assembly comprising:

a first rollable core with an engagement side and a base side;

a first cover having a first cover internal panel, said first cover for receiving said first rollable core therein with said first cover internal panel against said engagement side, said first cover having a first part of an attachment fastener extending along said first cover internal panel;

a second rollable core with a second core base side and a sleep side;

a second cover having a second cover internal panel, said second cover for receiving said second rollable core therein with said second cover internal panel against said second core base side, said second cover having a second part of the attachment fastener for mating with said first part and orienting said internal panels against one another with said base side and said sleep side disposed externally, said second part extending along said second cover internal panel.

2. The mattress assembly according to claim 1, wherein said first and second covers each have a respective openable fastener to allow for insertion of the respective cores.

3. The mattress assembly according to claim 2, wherein said openable fasteners are zippers disposed to extend along said internal panels.

4. The mattress assembly according to claim 3, wherein said zippers are behind said attachment fastener when said attachment fastener parts are mated with one another.

5. The mattress assembly according to claim 1, wherein said cores are each formed of high-density materials.

6. The mattress assembly according to claim 5, wherein said cores are each formed of multiple different layers of high-density latex.

7. The mattress assembly according to claim 1, wherein said cores combined have a weight of greater than 145 pounds.

8. The mattress assembly according to claim 1, wherein at least one of said internal panels is an anti-slip material.

9. The mattress assembly according to claim 1, wherein said attachment fastener is a zipper and said parts of said attachment fastener are respective zipper teeth sets.

10. A method of delivering and assembling a mattress assembly comprising:

providing a mattress assembly that is constructed of two rollable cores having a combined weight of greater than 145 pounds with each of the cores being less than 145 pounds, each of the cores having a respective internal side that rest against one another when the cores are assembled to one another;

providing each of the cores with a respective mattress cover each having a respective attachment fastener part that extends along the periphery of the internal surfaces;

individually rolling up, packaging and shipping the cores with the covers to an end user;

stacking the cores with the internal sides resting against one another;

connecting the attachment fastener parts to one another to complete the mattress assembly.

11. The method according to claim 10, wherein the cores are each formed of high-density material.

12. The method according to claim 11, wherein the high-density material is multiple layers of latex foam.