Interlocking foam encasement components to form mattress encasements, and related mattress encasements, mattress assemblies and methods

Abstract

Interlocking foam encasement components to form mattress encasements, and related mattress encasements, mattress assemblies, and methods are disclosed. A mattress encasement is formed by two interlocking foam encasement components engaged with each other. Each interlocking foam encasement component includes a foam base member with two foam side-support members provided in parallel or substantially parallel arrangement on opposite sides of the foam base member. To form the mattress encasement, first side-support members of a first interlocking foam encasement component are interlocked orthogonal or substantially orthogonal to second side-support members of a second interlocking foam encasement component to form a foam side-support perimeter for the mattress encasement. The foam side-support perimeter provides an interior area to receive and encase a mattress innerspring or mattress core. In this manner, as a non-limiting example, the mattress encasement can be easily assembled and the foam encasement members folded or rolled for reduced-volume storage and/or shipment.

We claim: 
     
         1 . A mattress encasement for encasing a mattress innerspring or mattress core, comprising:
 a first interlocking foam encasement component comprising a first foam base member having a first pair of foam side-support members provided on first opposite ends of the first foam base member and disposed in parallel or substantially parallel arrangement in a first longitudinal direction; and   a second interlocking foam encasement component comprising a second foam base member having a second pair of foam side-support members provided on first opposite ends of the second foam base member and disposed in parallel or substantially parallel arrangement in a second longitudinal direction;   the first interlocking foam encasement component received by the second interlocking foam encasement component to interlock the first pair of foam side-support members in the first longitudinal direction orthogonal or substantially orthogonal to the second longitudinal direction of the second pair of foam side-support members, forming a foam side-support perimeter; and   the foam side-support perimeter comprised of the first pair of foam side-support members interlocked with the second pair of foam side-support members and an interior area inside the foam side-support perimeter configured to encase a mattress innerspring or mattress core.   
     
     
         2 . The mattress encasement of  claim 1 , wherein the first pair of foam side-support members each have a first length greater than a second length of each of the second pair of foam side-support members. 
     
     
         3 . The mattress encasement of  claim 1 , wherein a first end face and second end face of each of the second pair of foam side-support members abuts a first side end and a second side end of each of the second pair of foam side-support members. 
     
     
         4 . The mattress encasement of  claim 1 , further comprising a first pair of slots disposed in the interior area between a bottom end of the first pair of foam side-support members and a support surface of the first foam base member, the first pair of slots configured to receive a pair of edges on second opposite ends of the second foam base member to interlock the second interlocking foam encasement component to the first interlocking foam encasement component. 
     
     
         5 . The mattress encasement of  claim 4 , wherein the second pair of foam side-support members extend beyond second opposite ends of the second foam base member. 
     
     
         6 . The mattress encasement of  claim 5 , wherein a first end face and second end face of each of the second pair of foam side-support members abuts a first side end and a second side end of each of the second pair of foam side-support members. 
     
     
         7 . The mattress encasement of  claim 1 , wherein at least one of:
 the first pair of foam side-support members are attached to the first foam base member; and   the second pair of foam side-support members are attached to the second foam base member.   
     
     
         8 . The mattress encasement of  claim 1 , wherein at least one of:
 the first pair of foam side-support members are integrally formed as part of the first foam base member; and   the second pair of foam side-support members are integrally formed as part of the second foam base member.   
     
     
         9 . The mattress encasement of  claim 1 , further comprising a plurality of elongated protrusions disposed in parallel or substantially parallel arrangement in the first foam base member providing a plurality of elongated channels disposed in the parallel or substantially parallel arrangement, each of the plurality of elongated channels disposed adjacent to at least one elongated protrusion among the plurality of protrusions. 
     
     
         10 . The mattress encasement of  claim 1 , further comprising at least one of:
 a first plurality of elongated channels disposed in parallel or substantially parallel arrangement in the first foam base member;   a second plurality of elongated channels disposed in parallel or substantially parallel arrangement in the first foam base member.   
     
     
         11 . The mattress encasement of  claim 1 , further comprising at least one of:
 at least one elongated cut portion disposed in a bottom surface of the first foam base member between second opposite ends of the first foam base member forming at least one bend bias channel in the first foam member; and   at least one elongated cut portion disposed in a bottom surface of the second foam base member between second opposite ends of the second foam base member forming at least one bend biased channel in the second foam member.   
     
     
         12 . The mattress encasement of  claim 11 , wherein at least one of:
 the at least one elongated cut portion disposed in the bottom surface of the first foam base member is comprised of: a first pair of elongated cut portions each disposed a width of a foam side-support member among the first pair of foam side-support members from the opposite ends of the first foam base member, and a second pair of elongated cut portions each disposed a height of a foam side-support member among the first pair of foam side-support members from the first pair of elongated cut portions disposed in the first foam base member, to facilitate folding of the first pair of foam side-support members about the first foam base member in unassembled form; and   the at least one elongated cut portion disposed in the bottom surface of the second foam base member is comprised of: a first pair of elongated cut portions each disposed a width of a foam side-support member among the second pair of foam side-support members from the opposite ends of the second foam base member, and a second pair of elongated cut portions each disposed a height of a foam side-support member among the second pair of foam side-support members from the first pair of elongated cut portions disposed in the second foam base member, to facilitate folding of the second pair of foam side-support members about the second foam base member in unassembled form.   
     
     
         13 . The mattress encasement of  claim 1 , further comprising at least one of:
 at least one first channel disposed in each of the first pair of foam side-support members; and   at least one second channel disposed in each of the second pair of foam side-support members.   
     
     
         14 . The mattress encasement of  claim 13 , wherein at least one of:
 the first pair of foam side-support members are integrally formed with the first foam base member; and   the second pair of foam side-support members are integrally formed with the first foam base member.   
     
     
         15 . The mattress encasement of  claim 14 , further comprising at least one:
 a first pair of living hinges disposed on opposite ends of the first foam base member, each of the first pair of foam side-support members flipped-up about a living hinge among the first pair of living hinges to provide the first pair of foam side-support members extending orthogonal to a support plane of the first foam base member; and   a second pair of living hinges disposed on opposite ends of the second foam base member, each of the second pair of foam side-support members flipped-up about a living hinge among the second pair of living hinges to provide the second pair of foam side-support members extending orthogonal to a support plane of the first foam base member.   
     
     
         16 . The mattress encasement of  claim 1 , further comprising a plurality of innerspring engaging protrusions disposed orthogonal or substantially orthogonal from at least one interior side of a plurality of interior sides of the first pair of foam side-support members and the second pair of foam side-support members into the interior area, the plurality of innerspring engaging protrusions configured to each be disposed between adjacent perimeter coils in a mattress innerspring disposed in the interior area. 
     
     
         17 . The mattress encasement of  claim 1 , wherein:
 the first pair of foam side-support members are comprised of a thermoplastic material; and   the second pair of foam side-support members are comprised of a thermoplastic material.   
     
     
         18 . The mattress encasement of  claim 1 , wherein:
 the first pair of foam side-support members are comprised of a thermoset material; and   the second pair of foam side-support members are comprised of a thermoset material.   
     
     
         19 . The mattress encasement of  claim 1 , further comprising a cloth member secured to a first foam side-support member among the first pair of side-support members and to a second foam side-support member among the second pair of side-support members disposed adjacent to the first foam side-support member, to secure the first foam side-support member to the second foam side-support member. 
     
     
         20 . The mattress encasement of  claim 19 , wherein the at least one cloth member is thermally bonded to the first foam side-support member among the first pair of side-support members and the second foam side-support member among the second pair of side-support members. 
     
     
         21 . The mattress encasement of  claim 19 , further comprising at least one fastener securing the first foam side-support member among the first pair of side-support members and to the second foam side-support member among the second pair of side-support members disposed adjacent to the first foam side-support member. 
     
     
         22 . The mattress encasement of  claim 1  provided in a mattress assembly. 
     
     
         23 . The mattress encasement of  claim 22 , further comprising a mattress innerspring or mattress core disposed in the interior area. 
     
     
         24 . A method of assembling a mattress encasement for encasing a mattress innerspring or mattress core, comprising:
 providing a first interlocking foam encasement component comprising a first foam base member having a first pair of foam side-support members provided on first opposite ends of the first foam base member and disposed in parallel or substantially parallel arrangement in a first longitudinal direction; and   providing a second interlocking foam encasement component comprising a second foam base member having a second pair of foam side-support members provided on first opposite ends of the second foam base member and disposed in parallel or substantially parallel arrangement in a second longitudinal direction; and   receiving the first interlocking foam encasement component by the second interlocking foam encasement component to interlock the first pair of foam side-support members in the first longitudinal direction orthogonal or substantially orthogonal to the second longitudinal direction of the second pair of foam side-support members, forming a foam side-support perimeter comprised of the first pair of foam side-support members interlocked with the second pair of foam side-support members and an interior area inside the foam side-support perimeter configured to encase a mattress innerspring or mattress core.