US 12,262,816 B2
Mattresses, methods of manufacture and components
Travis Wagner, Lexington, NC (US)
Assigned to Ashley Furniture Industries, LLC., Arcadia, WI (US)
Filed by Ashley Furniture Industries, LLC, Arcadia, WI (US)
Filed on Feb. 18, 2021, as Appl. No. 17/178,892.
Claims priority of provisional application 62/978,288, filed on Feb. 18, 2020.
Prior Publication US 2021/0251391 A1, Aug. 19, 2021
Int. Cl. B65B 5/04 (2006.01); A47C 27/00 (2006.01); A47C 27/06 (2006.01); A47C 31/10 (2006.01); B65D 75/00 (2006.01); B65D 85/64 (2006.01)
CPC A47C 27/002 (2013.01) [A47C 27/064 (2013.01); A47C 31/105 (2013.01); B65D 75/002 (2013.01); B65D 85/64 (2013.01); B65D 2585/647 (2013.01)] 9 Claims
OG exemplary drawing
 
1. A stack or compilation of completed and empty quilted mattress coverings for subsequent assembly with respective mattress cores for providing completed mattresses for retail sale, each of the mattress coverings comprising:
a quilted top panel component having a periphery, the quilted top panel component comprising a top exterior fabric panel with a peripheral edge portion, a thin interior fabric panel with a peripheral edge portion, at least one foam layer with a peripheral edge and at least one low density fiber layer sandwiched between the exterior fabric panel and the thin interior fabric panel, the quilted top panel having an ordered arrangement of connections extending through the top panel thereby securing together the top exterior fabric panel, the thin interior fabric panel, the at least one foam layer, and the at least one low density fiber layer;
a quilted sidewall border component extending around the entire periphery, the quilted sidewall border component comprising an exterior fabric strip with an upper edge portion and a lower edge portion, a thin interior fabric strip with an upper edge portion and a lower edge portion, a foam or fiber layer strip sandwiched between the exterior fabric strip and the thin interior fabric strip, the quilted sidewall border component secured to the quilted top panel component by tape edge extending about and sewn to the top exterior fabric panel peripheral edge portion, the thin interior fabric panel peripheral edge portion, the upper edge portion of the exterior fabric strip, and the upper edge portion of the interior thin fabric strip; and
a thin bottom fabric panel with an edge portion, the bottom fabric panel joined to the quilted sidewall border component by tape edge extending about and sewn to the thin bottom panel edge portion, the lower edge portion of the exterior fabric strip, and the lower edge portion of the thin interior fabric strip;
wherein the thin interior fabric panel of the quilted top panel component, the thin interior fabric strip of the quilted sidewall border component, and the thin bottom fabric panel of each quilted mattress covering define a mattress core receiving pocket sized to a common dummy core, and wherein the thin bottom fabric panel of each quilted mattress covering has a zipper extending along a plurality of four sides of a periphery of the thin bottom fabric panel for accessing the empty mattress core receiving pocket, and wherein each quilted mattress covering having five closed sides and one side openable and closeable with a zipper,
wherein each of the quilted mattress coverings are sized by the dummy core, and wherein the dummy core is completely coverable by each of the quilted mattress coverings.