Methods for manufacturing encased mattresses

Abstract

A mattress innercore support system in the form of a padded tray with a substantially rigid bottom panel. The tray has of a perimeter sidewall that is preferably made of foam and attached to the bottom panel. The system is compatible with (and sized for) all standard mattress cores, e.g., coil spring, pocketed spring, foam, foam/coil composite, and all known sizes. The mattress innercore is attached to the bottom panel by an adhesive, which simplifies assembly and reduces manufacturing cost of the mattress.

What is claimed is:  
     
         1 . A method of manufacturing a mattress, comprising: 
 providing a tray having a bottom panel and a perimeter sidewall, said bottom panel and perimeter sidewall forming a cavity,    applying an adhesive to the bottom panel inside the cavity at least proximate to the perimeter sidewall, and    placing an innercore inside the cavity,    wherein the innercore is secured to the bottom panel by the adhesive.    
     
     
         2 . The method of  claim 1 , further comprising 
 disposing an upholstery layer over a top surface of the innercore.    
     
     
         3 . The method of  claim 1 , wherein the perimeter sidewall is made of foam.  
     
     
         4 . The method of  claim 1 , wherein the bottom panel comprises a layer of high density foam.  
     
     
         5 . The method of  claim 1 , wherein the bottom panel forms a substantially rigid base platform that comprises a layer made of a material selected from the group consisting of wood, cardboard, plastic or foam, said material capable of providing support to the innercore.  
     
     
         6 . The method of  claim 1 , wherein the innercore comprises a plurality of spring coils.  
     
     
         7 . The method of  claim 1 , wherein the innercore is selected from the group of open coil innercores, fabric-encased spring coil innercores, and springs in foam innercore.  
     
     
         8 . The method of  claim 1 , wherein the innercore comprises a block of resilient foam.  
     
     
         9 . The method of  claim 1 , wherein providing the foam tray includes gluing the perimeter sidewall to a peripheral region of a major surface of the bottom panel.  
     
     
         10 . The method of  claim 9 , wherein the perimeter sidewall comprises a plurality of sidewall sections.  
     
     
         11 . The method of  claim 10 , wherein the perimeter sidewall comprises at least four foam sidewall sections.  
     
     
         12 . The method of  claim 10 , and further providing a wire for securing the innercore against the substantially rigid base platform.  
     
     
         13 . The method of  claim 1 , wherein the perimeter sidewall includes a joint for allowing the mattress to pivot between a reclined and an inclined position.  
     
     
         14 . A mattress comprising 
 a substantially rigid base platform;    a perimeter sidewall joined to the base platform, said platform and perimeter sidewall defining an interior cavity; and    an innercore disposed within the cavity,    wherein said innercore is secured to the bottom panel by an adhesive at least proximate to the perimeter sidewall.    
     
     
         15 . The mattress of  claim 14 , wherein the innercore comprises pocketed springs and the adhesive bonds fabric surrounding the pocketed springs to the bottom panel.