Unitary Elastic Mattress Cover and Method for Manufacturing Same

Abstract

A unitary mattress cover is disclosed. The mattress cover has a top panel and four side panels, which include two end side panels, a left side panel and a right side panel made from a single blank of fabric. Elastic materials are attached to at least a portion of the left and right side panels, and the left and right side panels are longer than the top panel in a longitudinal direction, and wherein free edges of the left and right side panels are attached to one of the two end side panels or to each other. Also disclosed is a method for making this unitary mattress cover in one continuous manufacturing process.

What is claimed is: 
     
         1 . A unitary mattress cover comprising a top panel and four side panels, which include two end side panels, a left side panel and a right side panel, wherein the top panel and the four side panels are made from a single blank of fabric,
 wherein elastic materials are attached to at least a portion of the left and right side panels,   wherein the left and right side panels are longer than the top panel in a longitudinal direction, and wherein free edges of the left and right side panels are attached to one of the two end side panels or to each other.   
     
     
         2 . The unitary mattress cover of  claim 1 , wherein the elastic materials comprise elastic yarns stitch-bonded to said at least portion of the left and right side panels. 
     
     
         3 . The unitary mattress cover of  claim 2 , wherein at least the top panel is stitch-bonded with elastic and/or inelastic yarns. 
     
     
         4 . The unitary mattress cover of  claim 3 , wherein the stitching on the top panel is different from the stitching on said at least portion of the left and right side panels. 
     
     
         5 . The unitary mattress cover of  claim 1 , wherein the single blank of fabric comprises a single layer of a woven, knit or nonwoven fabric. 
     
     
         6 . The unitary mattress cover of  claim 1 , wherein the elastic materials comprise elastic strips sewn to said at least portion of the left and right side panels. 
     
     
         7 . The unitary mattress cover of  claim 5 , wherein at least one of the top panel, the left panel and right panel further comprise an additional layer. 
     
     
         8 . The unitary mattress cover of  claim 7 , wherein said at least one additional layer comprises a cushion layer. 
     
     
         9 . The unitary mattress cover of  claim 7 , wherein said at least one additional layer comprises a film or a liquid resisting breathable membrane. 
     
     
         10 . The unitary mattress cover of  claim 2 , wherein the stitch-bonded yarns comprise re-stretchable cross gathering to facilitate form fitting and tucking around the edges under a mattress being covered by the unitary mattress. 
     
     
         11 . The unitary mattress cover of  claim 1  further comprising second elastic materials attached to said at least portion of the left and right side panels, wherein said second elastic materials are different than said elastic materials. 
     
     
         12 . A method for manufacturing a mattress cover comprising the steps of
 a) introducing a continuous fabric to a stitch-bonding or sewing equipment,   b) stitching an elastic yarn under tension to a top and a bottom portion of the fabric,   c) cutting a section of the stitch-bonded fabric to form a blank for a mattress cover,   d) slitting a plurality of lines in the stitch-bonded fabric or in the blank to separate end side panels and the left and right side panels, wherein the left and right side panels are formed from the stitch-bonded top and bottom portions, and   e) joining edges of the left and right side panels to each other or to one of the end side panels to form the mattress cover.   
     
     
         13 . The method of  claim 12 , wherein the tension of the elastic yarn is released after step e). 
     
     
         14 . The method of  claim 12 , wherein the end side panels and the left and right side panels are joined to a top panel. 
     
     
         15 . The method of  claim 14 , wherein the top panel is sized and dimensioned to fit a top of a mattress and the end side panels and the left and right side panels are sized and dimensioned to cover the sides of the mattress. 
     
     
         16 . The method of  claim 12 , wherein before step c) the fabric is held under tension and coupled to a jig to maintain tension. 
     
     
         17 . The method of  claim 14 , wherein at least one additional layer is introduced to the stitch-bonding or sewing machine. 
     
     
         18 . The method of  claim 17 , wherein the top panel is also stitch-bonded. 
     
     
         19 . The method of  claim 17 , wherein the at least one additional layer comprises a cushion layer. 
     
     
         20 . The method of  claim 17 , wherein the at least one additional layer comprises a film or a liquid resisting breathable membrane.