Encased innerspring mattress and method of making same

Abstract

A method of making a foam encased innerspring mattress and an innerspring mattress made according to the method. The method includes the steps of assembling the sides and bottom of a foam housing, positioning an innerspring unit in the housing, securing a foam layer to the top of the housing, and sealing the innerspring unit therein. A quilted covering is applied over the completed assembly. According to the method, a foam encased innerspring mattress can be made in any desired firmness, and any desired size or shape, including standard bedding sizes and shapes.

What is claimed is:  
     
         1 . A method of making a foam encased mattress, the method of comprising the steps of: 
 building a foam housing, including the steps of:    positioning first and second side rail pieces on edge and in parallel, spaced-apart alignment, applying adhesive to top edge surfaces of said side rails, positioning head rail pieces, and applying adhesive and adhering the head rail thereto, positioning foot rail pieces applying adhesive and adhering foot rail thereto, applying adhesive to top surfaces to said first and second side rail pieces, said head rail and said foot rail; positioning a first planar layer over said adhesive in registration with said side rail pieces, said head rail and said foot rail, and adhering said planar layer hereto respectively;    flipping over said foam housing;    positioning netting within said foam housing;    positioning an innerspring unit within said foam housing;    applying adhesive to top surfaces of said first and second side rail pieces, said head and said foot rail;    positioning a second planar layer over said adhesive in registration with said side rail pieces, said head rail and said foot rail, and adhering said planar layer thereto respectively.    
     
     
         2 . The method of  claim 1 , wherein said adhesive is a double-sided adhesive tape.  
     
     
         3 . The method of  claim 1 , further comprising the step of: 
 providing said foam encased mattress with a pillow-top.    
     
     
         4 . The method of  claim 1 , further comprising the step of: 
 covering said foam encased mattress with a quilted cover.    
     
     
         5 . A foam encased mattress, having a foam housing, the mattress comprising: 
 first and second side rails, a head rail, and a foot rail, said rails joined together in respective planar registration with one another to form a cavity;    a first planar foam layer disposed over and joined to a first surface of said foam housing;    a second planar foam layer disposed over and joined to a second surface of said foam housing;    and an innerspring unit, whereby said innerspring unit is sealed within said cavity by said rails and said planar foam layers.    
     
     
         6 . The foam encased mattress of  claim 5 , wherein said rails and said foam layers are joined together by double-sided adhesive tape.  
     
     
         7 . The foam encased mattress of  claim 6 , further comprising a pillow-top.  
     
     
         8 . The foam encased mattress of  claim 7 , further comprising a quilted cover.