Mattresses, methods of manufacture and components

Abstract

Mattress coverings are manufactured utilizing conventional equipment and using a dummy mattress core. The mattress coverings include a zippered access on the bottom panel, for example, where the dummy core can be removed after the mattress covering is completed. When shipped to a regional assembly facility the zippered access is utilized for insertion of a select mattress core that corresponds to the size of the dummy mattress core about which the mattress covering was assembled. The zippered access is zipped shut and the mattress is ready for sale, transport, and use. Great efficiencies are available where the mattress cover is assembled in a first location, shipped to a sale and use location and also regionally close to where mattress cores are manufactured, and the mattress covers are assembled with cores into mattresses.

I claim: 
     
         1 . A pillow top mattress cover for subsequent assembly with a mattress core for providing a completed pillow top mattress, each mattress comprising:
 a singular lower sidewall border component formed of quilted material, the lower sidewall border component attached by sewn tape edge to a bottom fabric panel having a zippered opening for subsequently receiving one of the mattress cores, the lower sidewall border component attached to an upper thin fabric panel and to an upper sidewall border component by sewn tape edge, the upper sidewall border component attached to a quilted top panel component by sewn tape edge, the quilted top panel component comprising an exterior fabric panel, an interior fabric layer and one or more foam and/or fiber fill layers therebetween,   each pillow top mattress cover further comprising a plurality of layers of cushioning material between the quilted top panel component and the upper thin fabric panel and a foam layer glued to and positioned below the upper thin fabric panel, the plurality of layers of cushioning material secured together with adhesive.   
     
     
         2 . The pillow top mattress cover of  claim 1 , wherein the pillow top mattress cover is placed in a stack, the stack being enclosed in a shipping container. 
     
     
         3 . The pillow top mattress cover of  claim 1 , wherein each mattress cover is vacuum packed. 
     
     
         4 . The pillow top mattress cover of  claim 1 , wherein each mattress cover is initially manufactured utilizing a dummy mattress core sized to the intended mattress core to be inserted. 
     
     
         5 . The pillow top mattress cover of  claim 1 , wherein each of the mattress covers have a transportation configuration, a final assembly configuration, and a use configuration, such that in the transportation configuration the singular sidewall border component folds in upon itself defining a flattened form having a maximum thickness of less than 6 inches, in the filling configuration the zipper is an in open position and a portion of the material panel is pulled back, and in the use configuration the mattress core is located within the cavity and the zipper is in a sealed position. 
     
     
         6 . The pillow top mattress cover of  claim 1 , wherein for each of the mattress covers, each component, each panel, and each layer of the mattress cover are secured together in an integrated assembly. 
     
     
         7 . A zippered mattress covering for subsequent assembly into a mattress comprising:
 a top portion having peripheral edges comprising an upward facing layer glued to an interior foam panel, the peripheral edges being secured to a top edge of a singular quilted sidewall border component with a tape seam, the top portion and singular sidewall border component defining a cavity having a similar length, width, and height of a mattress core; and   a bottom portion comprising a bottom material panel having four peripheral edges, wherein a first peripheral edge of the bottom material panel is fixedly attached to a first bottom peripheral edge of the singular sidewall border component, and a zipper defines an opening in the bottom material panel configured to receive the mattress core,   wherein the zippered mattress covering has a transportation configuration, a final assembly configuration, and a use configuration, such that in the transportation configuration the singular sidewall border component folds in upon itself, the folded portion having a maximum thickness of less than 18 inches, in the filling configuration the zipper is an in open position and a portion of the material panel is pulled back, and in the use configuration the mattress core is located within the cavity and the zipper is in a sealed position.   
     
     
         8 . The zippered mattress covering of  claim 7 , wherein an intermediate fabric panel is glued to the interior foam panel. 
     
     
         9 . The zippered mattress covering of  claim 8 , wherein a second foam panel is glued to the intermediate fabric panel. 
     
     
         10 . The zippered mattress covering of  claim 9 , wherein the second foam panel is egg crate foam. 
     
     
         11 . The zippered mattress covering of  claim 10 , wherein the egg crate foam has a textured surface opposite a flat surface, the textured surface positioned adjacent the mattress core and the flat surface being glued to the intermediate fabric panel. 
     
     
         12 . The zippered mattress covering of  claim 7 , wherein a planar sheet of egg crate foam is disposed between the mattress core and the top portion in the use configuration. 
     
     
         13 . The zippered mattress covering of  claim 7 , wherein the zipper forms a “U” shape. 
     
     
         14 . The zippered mattress covering of  claim 7 , wherein the zippered mattress covering in the use configuration is has dimensions conforming to one of a twin, extra long, double, queen, king, or California king mattress. 
     
     
         15 . A mattress cover for subsequent assembly with a mattress core, the mattress cover 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 or matrixical 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 sidewall border component extending around the entire periphery, the 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 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;   a thin bottom fabric panel with an edge portion, the bottom fabric panel joined to the 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 define a mattress core receiving pocket, and wherein the thin bottom fabric panel has a zipper extending along three of four sides of a periphery of the thin bottom fabric panel for accessing the mattress core receiving pocket.