System and method for securing flexible foam mattress covers from misalignment

Abstract

A mattress covering system and associated method including a flexible foam mattress core having a top surface, a bottom surface and side walls connecting the top and bottom surfaces, a mattress cover made of a flexible and stretchable material, and a fabric connector mounted to the flexible foam core and coupled to at least a portion of the mattress cover to alleviate the possibility of misalignment during compression packing or extended use of the flexible foam mattress core.

1 . A mattress covering system comprising:
 a flexible foam mattress core, having a top surface, a bottom surface and side walls connecting the top and bottom surfaces;   a mattress cover made of a flexible and stretchable material; and   a fabric connector mounted to the flexible foam core and coupled to at least a portion of the mattress cover to alleviate the possibility of misalignment during compression packing or extended use of the flexible foam mattress core.   
     
     
         2 . The mattress covering system of  claim 1 , wherein the flexible foam mattress core comprises one to a plurality of support layers. 
     
     
         3 . The mattress covering system of  claim 1 , wherein the mattress cover comprises a top cover which is disposed over the top surface of the flexible foam mattress core and over the side walls, wherein the top cover of the mattress cover is coupled to a bottom cover of the mattress cover disposed over the bottom surface of the flexible foam mattress. 
     
     
         4 . The mattress covering system of  claim 1 , wherein the fabric connector comprises a single sheet of fabric secured to the bottom surface or top surface of the flexible foam mattress core. 
     
     
         5 . The mattress covering system of  claim 1 , wherein the fabric connector comprises a fabric connector that extends out over an edge of the flexible mattress core. 
     
     
         6 . The mattress covering system of  claim 1 , wherein the fabric connector comprises a single sheet of fabric that extends along the perimeter of the flexible mattress core coupled to the side walls and extending out over an edge of the flexible mattress core. 
     
     
         7 . The mattress covering system of  claim 1 , wherein the fabric connector comprises a plurality of tabs or sheet segments secured on the bottom surface, the top surface or the sidewalls of the flexible mattress core. 
     
     
         8 . The mattress covering system of  claim 1 , wherein the flexible mattress core comprises multiple layers and wherein at least a portion of the fabric connector is captured between adjacent layers. 
     
     
         9 . The mattress covering system of  claim 1 , further comprising a mattress closure to couple a top cover of the mattress cover to a bottom cover of the mattress cover and to the fabric connector. 
     
     
         10 . The mattress covering system of  claim 9 , wherein the mattress closure is made using a tape edge mattress closing technique comprising the gathering up of the fabric connector, with the top cover of the mattress cover and the bottom cover of the mattress cover and bringing them together in a sewn closure. 
     
     
         11 . A mattress covering system comprising:
 a flexible foam mattress core including one to a plurality of support layers, the flexible foam mattress having a top surface, a bottom surface and side walls connecting the top and bottom surfaces;   a mattress cover made of a flexible and stretchable material, the mattress cover having a top cover which is disposed over the top surface of the flexible foam mattress core and over the side walls, and the top cover being coupled to a bottom cover of the mattress cover disposed over the bottom surface of the flexible foam mattress;   a fabric connector mounted to the flexible foam core and coupled to at least a portion of the mattress cover to alleviate the possibility of misalignment during compression packing or extended use of the flexible foam mattress core; and   a mattress closure coupled to the top cover of the mattress cover, to the bottom cover of the mattress cover and to the fabric connector to bring the top cover, the bottom cover and the fabric connector together in a sewn closure.   
     
     
         12 . The mattress covering system of  claim 11 , wherein the fabric connector comprises a single sheet of fabric mounted to the bottom surface or top surface of the flexible foam mattress core. 
     
     
         13 . The mattress covering system of  claim 11 , wherein the fabric connector comprises a fabric connector that extends out over an edge of the flexible mattress core. 
     
     
         14 . The mattress covering system of  claim 11 , wherein the fabric connector comprises a single sheet of fabric that extends along the perimeter of the flexible mattress core coupled to the sidewalls. 
     
     
         15 . The mattress covering system of  claim 11 , wherein the fabric connector comprises a plurality of tabs or sheet segments mounted on the bottom surface, the top surface or the sidewalls of the flexible mattress core. 
     
     
         16 . The mattress covering system of  claim 11 , wherein at least a portion of the fabric connector is captured between adjacent layers of the flexible foam core. 
     
     
         17 . A method for securing a mattress cover to a foam mattress comprising:
 providing a flexible foam mattress core including one to a plurality of support layers, the flexible foam mattress having a top surface, a bottom surface and side walls connecting the top and bottom surfaces;   mounting a fabric connector to at least a portion of the flexible foam core;   enveloping the flexible foam mattress in a mattress cover made of a flexible and stretchable material, the mattress cover having a top cover which is disposed over the top surface of the flexible foam mattress core and over the side walls, and the top cover being coupled to a bottom cover of the mattress cover disposed over the bottom surface of the flexible foam mattress; and   coupling the fabric connector to the mattress cover to alleviate the possibility of misalignment during compression packing or extended use of the flexible foam mattress core.   
     
     
         18 . The method of  claim 18 , wherein mounting the fabric connector to at least a portion of the flexible foam core comprises mounting a single sheet of fabric secured to the bottom surface or top surface of the flexible foam mattress core. 
     
     
         19 . The method of  claim 18 , wherein mounting the fabric connector to at least a portion of the flexible foam core comprises mounting a single sheet of fabric that extends along the perimeter of the flexible mattress core coupled to the side walls and extending out over an edge of the flexible mattress core. 
     
     
         20 . The method of  claim 18 , wherein mounting the fabric connector to at least a portion of the flexible foam core comprises mounting a plurality of tabs or sheet segments to the bottom surface, the top surface or the sidewalls of the flexible mattress core.