Method of assembling mattresses using plastic tab fasteners

Abstract

The invention, in various embodiments, is directed to mattress components coupled together by plastic fasteners. In particular, the mattress component comprise elements relating to the foam encasement of the innerspring mattress core. In various embodiments, the invention pertains to a method of assembling portions of the foam encasement using plastic tab fasteners. In various implementations, the plastic tab fasteners comprise T-End™ fasteners.

1 . A mattress comprising: 
 an innerspring unit;    a foam encasement for enclosing the innerspring unit having: 
 a plurality of foam encasement elements;  
 one or more fasteners fastening the plurality of foam encasements together, the fasteners having a least one end terminating in a substantially perpendicular end; and  
   an outer cover covering at least a portion of the foam encasement.    
     
     
         2 . The mattress according to  claim 1  wherein, the plurality of foam encasement elements comprise foam side rails.  
     
     
         3 . The mattress according to  claim 1  wherein, one or more of foam encasement elements comprise a substantially planar piece of foam.  
     
     
         4 . The mattress according to  claim 2  wherein, the side rails are abutted up against one another to form an interface.  
     
     
         5 . The mattress according to  claim 2  wherein, the foam side rails are mitered.  
     
     
         6 . The mattress according to  claim 2  wherein, the foam side rails are composed of, at least in part, polyurethane foam.  
     
     
         7 . The mattress according to  claim 2  wherein, the fasteners comprise a polymer.  
     
     
         8 . The mattress according to  claim 7  wherein, the fasteners are plastic tab fasteners.  
     
     
         9 . The mattress according to  claim 8  wherein, the plastic tab fasteners have ends terminating in a substantially perpendicularly direction relative to the main body of the plastic tab fastener.  
     
     
         10 . The mattress according to  claim 1  wherein, the fasteners are T-End fasteners.  
     
     
         11 . The mattress according to  claim 3  wherein, the substantially planar piece of foam is in the form of a sheet.  
     
     
         12 . The mattress according to  claim 1  wherein, one or more foam encasement elements is side rail.  
     
     
         13 . The mattress according to  claim 12  wherein, the one or more side rails form, at least in part, a perimeter.  
     
     
         14 . The mattress according to  claim 11  wherein, the substantially planar piece of foam is substantially the size of the outer perimeter and disposed adjacent to the perimeter.  
     
     
         15 . The mattress according to  claim 14  further comprising a second substantially planar piece of foam, being substantially the size of the outer perimeter and disposed adjacent and opposite to the foam encasement relative to the substantially planar piece of foam.  
     
     
         16 . The mattress according to  claim 1  wherein, the fasteners comprise a polymer.  
     
     
         17 . The mattress according to  claim 1  wherein, the innerspring unit is an open coil configuration, or an Marshall coil configuration.  
     
     
         18 . The mattress according to  claim 1  wherein, the outer covering is substantially flame retardant.  
     
     
         19 . A method for assembling a foam encasement for enclosing pocketed coils contained in a mattress comprising: 
 providing a fastening tool having a needle for inserting and disposing fasteners through foam or fabric, the fasteners having a least one end terminating in a substantially perpendicular end;    providing a first and second foam encasement element; and    assembling the first and second foam encasement elements by: 
 inserting the needle into the first foam encasement element;  
 continuing to insert the needle into the second foam encasement element; and  
 actuating the fastening tool for disposing the fastener in a predetermined location.  
   
     
     
         20 . The method according to  claim 19  wherein, the first and second foam encasement elements are side rails.  
     
     
         21 . The method according to  claim 20  wherein, the side rails are mitered to form a corner joint.  
     
     
         22 . The method according to  claim 21  wherein, the needle is inserted through the mitered faces of the side rails at the corner joint.  
     
     
         23 . The method according to  claim 19  wherein, the first foam encasement element is a bottom foam base.  
     
     
         24 . The method according to  claim 23  wherein, the fastening tool is inserted through the bottom foam base and partially through the second foam encasement element.  
     
     
         25 . The method according to  claim 24  wherein, the second foam encasement element is a side rail.  
     
     
         26 . The method according to  claim 19  wherein, the fasteners comprise a polymer.  
     
     
         27 . The method according to  claim 26  wherein, the fasteners are plastic tab fasteners having longitudinal axes.  
     
     
         28 . The method according to  claim 27  wherein, the plastic tab fasteners have two ends and at least one of the two end terminating in a substantially perpendicularly relative to the longitudinal axis of the plastic tab fastener.  
     
     
         29 . The method according to  claim 19  wherein, the fasteners are T-End fasteners.