U.S. patent application number 11/186505 was filed with the patent office on 2007-01-25 for method of assembling mattresses using plastic tab fasteners.
This patent application is currently assigned to DREAMWELL, LTD.. Invention is credited to William C. Creekmuir.
Application Number | 20070017034 11/186505 |
Document ID | / |
Family ID | 37677701 |
Filed Date | 2007-01-25 |
United States Patent
Application |
20070017034 |
Kind Code |
A1 |
Creekmuir; William C. |
January 25, 2007 |
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.TM. fasteners.
Inventors: |
Creekmuir; William C.;
(Atlanta, GA) |
Correspondence
Address: |
FISH & NEAVE IP GROUP;ROPES & GRAY LLP
ONE INTERNATIONAL PLACE
BOSTON
MA
02110-2624
US
|
Assignee: |
DREAMWELL, LTD.
Las Vegas
NV
|
Family ID: |
37677701 |
Appl. No.: |
11/186505 |
Filed: |
July 21, 2005 |
Current U.S.
Class: |
5/717 ;
29/91.1 |
Current CPC
Class: |
B68G 15/00 20130101;
A47C 31/026 20130101; B68G 7/054 20130101; Y10T 29/481
20150115 |
Class at
Publication: |
005/717 ;
029/091.1 |
International
Class: |
A47C 23/04 20060101
A47C023/04 |
Claims
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.
Description
TECHNICAL FIELD
[0001] This invention generally relates to systems and method for
constructing mattresses.
BACKGROUND
[0002] Spring mattresses have been in use for over 100 years.
Existing spring mattresses use a variety of spring types to form
their inner core. Perhaps the most common is the traditional wire
spring assembly having a set of interconnected wire spring coils.
Another type of spring assembly is the so-called Marshall
construction that was developed in the late 1890's by Marshall
Mattress of Toronto, Canada. The Marshall design utilizes fabric
pockets to encapsulate each spring. In this way, the coils may flex
separately from each other.
[0003] Generally, mattresses are formed with a mattress central
portion surrounded by a mattress border construction. The mattress
central portion may include a series of coil springs (Marshall
springs) connected together, which can be enclosed in fabric
pocket. Alternatively, the mattress central portion may comprise
polyurethane or latex foam layers or synthetic or natural fibers,
optionally in combination with springs. To provide sufficient
support and to make the mattress more robust, mattress
manufacturers have introduced mattresses with a foam-encased
innercore that gives greater edge support. The foam edge is
typically glued to a support layer and the coil unit is joined to
the support layer by a border wire and hog rings. The sleeping
surface of the mattress is typically covered with a quilted
fabric.
[0004] When manufacturing the mattress, the innerspring unit is
typically attached to a lower border wire and that border wire is
joined to the support layer. The foam edge is glued in place around
the innerspring unit. The quilted fabric is then attached to side
panels by sewing.
[0005] It should be noted that conventional high-end mattress
manufacturing techniques employ an adhesive to secure together
components of the mattress (and, in particular, foam encasement
components) prior to sewing the outer layer of quilted cotton
material around the remainder of the mattress. Specifically, one or
both of the contact surfaces of adjacent foam encasement components
are sprayed with an adhesive. With the adhesive sprayed onto one or
both of the contact surfaces of adjacent layers, the components are
first aligned and then drawn into contact with one another.
[0006] Components of the foam encasements, which are traditionally
glued together, present the following disadvantages. The use of
adhesives to secure together foam encasement components of a
mattress results in a significant level of waste. Specifically, if
the components of material are secured misaligned, there is no
means to separate them and attempt to re-secure the foam encasement
components. As a result, foam encasement components which are
misaligned are often discarded as waste, thereby increasing
manufacturing costs, which is highly undesirable.
[0007] As a second drawback, the use of adhesives to secure
together foam encasement components of a mattress may create an
unpleasant amount of fumes and mess, which is undesirable.
[0008] As a third drawback, the use of adhesives to secure together
foam encasement components of a mattress often creates audible
crackling sounds as the adhesives age, which is highly
undesirable.
[0009] Although traditional mattresses and manufacturing processes
work well, there is a need in the art for improved techniques for
manufacturing mattresses that are easier to manufacture by enabling
efficient assembly of the foam encasement components before the
mattress is sewn closed.
SUMMARY OF THE INVENTION
[0010] The system and methods described herein address the
deficiencies of the prior art by providing a method of
manufacturing a mattress that includes the steps of providing a
mattress core, providing a plurality of foam encasement components
and affixing the plurality of foam encasement components together
by inserting tab fasteners through or into the foam encasement
components. In various implementations, the foam encasement
components comprise side rails, and optionally, include a top or
bottom upholstery foam cover.
[0011] In one aspect, the mattress includes a foam encasement
comprising foam side rails which are affixed to one another using
tab fasteners. According to some embodiments, the foam encasement
has a top or bottom foam deck which is attached to the side rail
with the tab fasteners.
[0012] According to another aspect, a mattress includes a mattress
core, at least one side rail joined to the mattress core by one or
more tab fasteners that have a strength sufficient to maintain a
relative position between the mattress core and the side rail. In
some configurations, plastic tab fasteners affix a plurality of
side rails together to form a frame around the mattress core.
[0013] Embodiments of the invention may include, among other
things, top or bottom foam decks which serve to encase the mattress
core. The mattress may include an upholstery layer defining a sleep
surface and applied over the top foam deck. The upholstery layer
may be permanently secured to the at least one side rail by a
mechanical fastener.
[0014] According to one feature of the invention, plastic tab
fasteners can be used to affix flange material associated with top
and bottom finished panels to the foam encased unit.
[0015] According to certain implementations, the plastic tab
fastener may be, but not necessarily, in the form of a conventional
heavy duty plastic tab fastener, as is known it the art. The
plastic tab fastener may comprise a 8 cm plastic member which
includes a first end shaped to define a cross-bar. The plastic tab
fastener may further include a second end similarly shaped to
define a cross-bar.
[0016] In certain embodiments, the plastic tab fastener can be
mass-produced in a unitary form known commonly as fastener stock.
The fastener stock is constructed in a clip-type assembly in which
individual plastic tab fasteners are arranged in a spaced,
side-by-side orientation, with the respective cross-bars parallel
to one another.
[0017] Optionally, plastic tab fasteners are disposed with the foam
encasement elements by a conventional plastic tab fastener
dispenser. For example, a plastic tab fastener dispenser may be
employed for attachment of: (1) flange material associated with top
and bottom finished panels to the foam encased unit, (2) top
upholstery foams to pocket coil innerspring units and foam side
rails, (3) bottom upholstery foam and pocket coil innerspring units
and foam side rails, (4) foam or other side rails to encase a
mattress core unit, and (5) side rails to other side rails in
corners of a mattress.
[0018] The mattress core can be an open coil mattress core, a
fabric-encased spring coil mattress core, or springs disposed in
foam mattress core. Alternatively, the mattress core can be one or
more blocks of resilient foam that can have different firmness.
[0019] This technique may eliminate the need for hot melt spray
adhesives, water and solvent spray glues, and acrylic adhesive
films which present safety hazards for operators. This technique
further reduces the need for mechanical fasteners, hook and loop
fastening, and any other techniques requiring additional hardware
or additional assembly time in the mattress manufacturing process.
The mattress described herein are less costly to manufacture while
offering more consistency in the manufacturing processing.
[0020] Further features and advantages will be apparent from the
following description of preferred embodiments and from the
claims.
BRIEF DESCRIPTION OF THE DRAWING
[0021] These and other features and advantages of the invention
will be more fully understood by the following illustrative
description with reference to the appended drawings, in which like
elements are labeled with like reference designations and which may
not be to scale.
[0022] FIG. 1 is an illustration of the pocketed coil innerspring
unit framed by foam side rails according to an illustrated
embodiment of the invention;
[0023] FIG. 2 is a three quarter view of a corner joint being
secured with plastic tab fasteners according to another illustrated
embodiment of the invention;
[0024] FIG. 3 is a three quarter view depicting the attachment of
bottom foam decking using plastic tab fasteners and the result
according to FIG. 2;
[0025] FIG. 4 is a three quarter view illustrating the attachment
of top foam decking using plastic tab fasteners and the result
according to FIG. 2;
[0026] FIG. 5 is a top longitudinal view of bottom foam decking
being secured with plastic tab fasteners according to an
illustrated embodiment of the invention.
[0027] FIG. 6 is a top three quarter view exemplifying the
attachment of side panels of a quilted top cover to the side rails
of a mattress assembly;
[0028] FIG. 7 is a front, bottom perspective view of a tool for
dispensing a plastic tab fasteners with a clip of two fasteners
loaded therein;
[0029] FIG. 8 is a front, bottom, right end perspective view of the
tool shown in FIG. 7 with a clip of fasteners loaded therein;
and
[0030] FIG. 9 is an enlarged, front perspective view of the
fastener guide assembly shown in FIG. 8.
ILLUSTRATIVE DESCRIPTION
[0031] As described above in summary, the invention is generally
directed to mattress construction and a manufacturing process for a
mattress that facilitates securing various mattress components
before the mattress is closed by sewing. The following illustrative
embodiments are described with respect to methods for securing side
rails and top and bottom foam decking or rails using plastic tab
fasteners. However, the article of manufacture and methods may be
used to secure any suitable component of the foam encasement using
any suitable plastic fastener.
[0032] A mattress spring unit typically includes an upper frame and
a lower frame which are spaced slightly apart and which are
arranged in a substantially parallel configuration. Each frame
(also commonly referred to as a wire box) includes a rigid and
durable wire, or rod, which is formed into a substantially
rectangular design, the wire defining the outer periphery of its
associated frame. In addition, a mattress spring unit typically
comprises a plurality of uniformly spaced apart metal springs, or
coils, which extend between the upper and lower frames. Each spring
includes a longitudinal axis which extends substantially at a right
angle relative to the upper and lower frames. As can be
appreciated, the plurality of springs enables the upper frame to
move, or give, towards the lower frame when a downward force is
applied onto the upper frame. As a result, when an individual rests
on the upper frame of the spring unit, the body weight of said
individual is uniformly absorbed by the plurality of springs, which
is highly desirable.
[0033] The collective plurality of springs, called the mattress
core, is surrounded by foam rails more specifically. The outer
periphery of the mattress core is framed by a plurality of foam
side rails. Typically, the mattress core is secured by the foam
side rail frame which is adhered thereto. The mattress core
encasement is completed by the addition of floor and ceiling foam
sheets or layers which are disposed below and above, respectively,
the mattress core. Top and bottom foam decking is secured to the
mattress core by adhering the foam decking to the foam side rails.
A foam encasement, as disclosed herein, can be any or all elements
of the mattress core encasement. For example, the foam encasement
can include side rail, a perimeter, or a top deck affixed to one or
more side rails.
[0034] To provide an overall understanding of the invention,
certain illustrative practices and embodiments will now be
described, including a manufacturing process for a mattress that
attaches an innerspring or coil unit to a plurality of side rails
and top or bottom foam decks before the mattress is closed by
sewing. However, it will be understood by one of ordinary skill in
the art that the systems and methods described herein can be
adapted and modified and applied in other applications and that
such other additions, modifications and uses will not depart from
the scope hereof.
[0035] FIG. 1 depicts an exemplary side rail frame 10 and a
pocketed innerspring unit 16 (mattress core) having pocketed
(Marshall) coil springs arranged in rows. Instead of pocketed coil
springs, the innerspring unit can also have an open coil mattress
core or a foam mattress core. The outer rows of the coil springs of
the pocketed innerspring unit 16 borders the side rail frame
10.
[0036] Side rail frame 10 includes a plurality of foam side rails
12a-d. Foam side rails 12a-d are made, for example, of polyurethane
foam having a selected ILD or another suitable material known to
those skilled in the art. In one embodiment, such as the one
illustrated in FIG. 1, the corners of foam side rails 12a-d are
mitered to facilitate coupling. However, the interface between the
foam side rails 12a-d can take on any suitable shape or
relationship, such as, a flat abutment or a saw tooth
configuration.
[0037] Foam side rails 12a-d are secured to one another with
plastic tab fastener 14a-d. For example, the mitered interfaces of
foam side rails 12a, 12b are secured to one another with plastic
tab fastener 14a. Similarly, foam side rails 12b, 12c are secured
via plastic tab fastener 14b. Mitered faces of foam side rails 12c,
12d are secured to one another with plastic tab fastener 14c.
Likewise, foam side rails 12c, 12d are secured via plastic tab
fastener 14d.
[0038] Referring now to FIG. 2, there is shown a perspective,
overhead view of a side rail frame constructed according to the
teachings herein. More particularly, FIG. 2 illustrates the process
by which the side rail frame 10, as depicted in FIG. 1, is
assembled. Side rail frame 10, at least in part, comprises foam
side rails 22a, 22b. In practice, foam side rails are assembled
using plastic tab fastener dispenser 24. Plastic tab fastener
dispenser 24, which will be described in more detail later,
comprises plastic tab fastener clip 28 and insertion tip 26. The
insertion tip penetrates foam side rails 22a, 22b and disposes a
plastic tab fastener from the plastic tab fastener clip 28. General
descriptions of the plastic tab fastener and dispenser will be
discussed in more detail below.
[0039] It should be noted that additional layers may be inserted
into the foam side rail framing. For example, on or more additional
layers of foam can be penetrated by insertion tip 26 during the
securing process of the foam side rails 22a, 22b.
[0040] FIG. 3 illustrates an exemplary mattress assembly wherein,
foam decking is being secured to a side rail frame, according to
another embodiment of the present invention. Specifically, FIG. 3
shows a perspective view of a mattress assembly, with bottom foam
deck 36 being attached to three side rails 34a, 34b, and 34c which
encloses an innerspring unit 35. Those skilled in the art will
appreciate that the plurality of side rails 34a, 34b, and 34c can
be provided to substantially surround the lateral sides of the
innerspring unit 35. Alternatively, the side rail surrounding the
innerspring unit 35 may be made of a single piece made, for
example, by an extrusion process without diverging from the spirit
of the present embodiment.
[0041] Side rails 34a, 34b, and 34c are secured pursuant to the
process elucidated in FIG. 2. In particular, side rails 34a, 34b,
and 34c comprise mitered ends and are secured using plastic tab
fasteners. Specifically, side rails 34a, 34b are coupled together
by plastic tab fasteners 32c, 32d using a plastic tab fastener
dispenser (not shown). Side rails 34b, 34c are similarly secured
using plastic fasteners 32a, 32b.
[0042] After the side rails 34a, 34b, and 34c (and a fourth side
rail, not shown) are secured together thereby forming a frame
around the periphery of the innerspring unit 20, the bottom foam
deck 36 is secured to the side rail frame. Bottom foam deck 36 is
adhered to the mattress assembly using a plastic tab fastener
dispenser which will be discussed in greater detail below. Plastic
tab fasteners 38a, 38b, 38c, and 38d secure bottom deck foam 36 to
side rail framing. (Plastic tab insertion will be discussed in
greater detail below.) Specifically, plastic tab fasteners 38a, 38b
secure bottom foam deck 36 by insertion of plastic tab fasteners
38a, 38b into side rail 34a. Similarly, plastic tab fasteners 38c,
38d secure bottom foam deck 36 by insertion of plastic tab
fasteners 38c, 38d into side rail 34c.
[0043] Referring to FIG. 4, after the bottom foam deck 36 is
secured to the mattress assembly, top foam deck 46 is applied. FIG.
4 shows a perspective view of a mattress assembly, with top foam
deck 46 being attached to three side rails 44a, 44b, and 44c which
encloses an innerspring unit 35. It can be appreciated that the
plurality of side rails 44a, 44b, and 44c can be provided to
substantially surround the lateral sides of the innerspring unit
35. Alternatively, the side rail surrounding the innerspring unit
35 may be made of a single piece made, for example, by an extrusion
process.
[0044] Side rails 44a, 44b, and 44c are secured pursuant to the
process elucidated in FIG. 2. Particularly, side rails 44a, 44b,
and 44c comprise mitered ends and are secured by plastic tab
fasteners. Side rails 44a, 44b are coupled together by plastic tab
fasteners 42c, 42d using a plastic tab fastener dispenser (not
shown). Side rails 44b, 44c are similarly secured by plastic
fasteners 42a, 42b.
[0045] After the side rails 44a, 44b, and 44c (and a fourth side
rail, not shown) are secured together thereby forming a side rail
frame around the periphery of the innerspring unit 20, the top foam
deck 46 is secured the side rail frame. Top foam deck 46 is adhered
to the mattress assembly using a plastic tab fastener dispenser
which will be discussed in greater detail later in the disclosure.
Plastic tab fasteners 48a, 48b, 48c, and 48d secure top foam deck
46 to side rail framing. Specifically, plastic tab fasteners 48a,
48b secure top foam deck 46 by insertion of plastic tab fasteners
48a, 48b into side rail 44a. Similarly, plastic tab fasteners 48c,
48d secure top foam deck 46 by insertion of plastic tab fasteners
48c, 48d into side rail 44c.
[0046] As shown in FIG. 5, to manufacture the mattress assembly in
accordance with FIG. 3 and FIG. 4, the top or bottom foam decking
can be affixed to the planar face of the innerspring unit (not
shown) using plastic tab fastener dispenser 56. The plastic tab
fastener dispenser 56 has an insertion tip 58. In one or more
embodiments, the insertion tip 58 does not penetrate entirely
through the foam components. In practice, it has been discovered
that this method of attachment is an effective means for adhering
components, especially in closed cell type materials. For example,
as depicted in FIG. 5, top or bottom foam decking 52 is affixed to
side rail 54 by piercing through top or bottom foam decking 52 and
penetrating into, but not through, side rail 54.
[0047] Alternatively, the side rail frame (partially comprised by
side rail 54) surrounding the innerspring unit may be made of a
single piece made, for example, by an extrusion process.
Accordingly, top or bottom foam decking can be affixed to an
extruded rail frame (not shown) by piercing through top or bottom
foam decking and penetrating into, but not through, the extruded
rail frame.
[0048] FIG. 6 shows an embodiment of a mattress assembly 64 with
side panels 68a, 68b installed over the side rails 62a, 62b for
permanently installing a quilted top panel. Quilted top panel 60 is
attached to the foam encasement unit, which surrounds the
innerspring unit, using plastic tab fasteners. Specifically, side
panel 68a of the quilted top panel 60 is pulled down and is affixed
to side rail 62a by piercing through side panel 68a and penetrating
into, but not through, side rail 62a. Side panel 68b of the quilted
top panel 60 is similarly pulled down and affixed to side rail 62b
by piercing through side panel 68b and penetrating into, but not
through, side rail 62b.
[0049] Referring now to FIGS. 7 and 8, there are shown various
views of an embodiment of a tool for use in dispensing one or more
plastic fasteners. As will be described further below, tool 70 is
designed principally for use in installing heavy-duty plastic
fasteners, such as fastener 31, through various mattress
components, such as those used to construct a foam encasement.
[0050] Compressed air powers tool 70 to dispense plastic fasteners.
Tool 70 can be derived from EHD T-end system, such as, an extra
heavy duty T-end fastener dispensing tool of the type manufactured
and sold by Avery Dennison Corporation of Pasadena, Calif.
[0051] Tool 70 comprises a protective housing 75 which is
constructed of a rigid and durable material. Housing 75 comprises a
right side casing 77 and a left side casing 79 which are secured
together by screws. Housing 75 additionally includes a nose 72
which is secured onto the leading end of casings 77 and 79 by
screws. Nose 72 is adapted to receive an elongated, extra
heavy-duty T-end, hollow, slotted needle 71.
[0052] Needle 71 is manufactured to have a length which is
considerably longer than other types of conventional extra
heavy-duty T-end, hollow, slotted needles. Specifically, needle 71
is preferably approximately 8 cm in length, thereby enabling it to
penetrate through two side rails of the foam encasement unit.
However, it is to be understood that tool 70 can have needles of
any length.
[0053] Tool 70 includes a pneumatically-driven ejection mechanism.
Specifically, tool 70 has a pneumatically driven cylinder 73.
Pneumatically driven cylinder 73 includes an air chamber and a
telescopingly mounted push rod (not shown) which actuates in the
axial direction. In practice, the activation and deactivation of
drive cylinder 73 serves to longitudinally displace a slide which
advances an ejector rod through tool 70. In particular, ejector rod
(not shown) is aligned to selectively protrude axially through
needle 71 so as to expel the cross-bar 85 of a fastener 81 out
through the open tip of needle 71.
[0054] Activation and deactivation of drive cylinder 73 is
controlled through a finger switch assembly 80. Finger switch
assembly 80 allows tool 70 to be operated by hand, which is highly
desirable.
[0055] Plastic tab fastener 81 is preferably in the form of a heavy
duty plastic fastener. In particular, plastic tab fastener 81 can
be in the form of an H-shaped heavy duty fastener of the type sold
by Avery Dennison Corporation as part of the Extra Heavy Duty
T-end.RTM. system. Specifically, plastic tab fastener 81 is a 3
inch plastic member which includes a first end shaped to define a
cross-bar 83 (also commonly referred to as a "T-bar") a second end
similarly shaped to define a cross-bar 85, (also commonly referred
to as a "T-bar"), and a thin filament 87 interconnecting cross-bars
83 and 85.
[0056] Plastic tab fasteners can be mass-produced in a unitary form
known commonly as fastener stock (as shown as plastic tab fastener
clip 28 in FIG. 2). The fastener stock is constructed in a
clip-type assembly in which individual plastic fasteners are
arranged in a spaced, side-by-side orientation, with the respective
cross-bars 83 and 85 and parallel to one another, each of
cross-bars being joined to a common, orthogonally-disposed runner
bar 89 by a severable connector 87. Plastic tab fastener clip is
typically manufactured through the process of injection molding. In
practice, plastic tab fastener clip, at least in part, is disposed
in fastener guide assembly 90 which will now be described in
greater detail.
[0057] Turning to FIG. 9, fastener guide assembly 90 comprises a
fastener guide 93 and a pair of guide covers 95a and 95b which
together define a partially enclosed channel 96 for receiving
runner bar 89, severable connectors 87, and cross-members 85 of the
fastener clip. It can be appreciated that fastener guide assembly
90 is provided with a curved construction in order to maintain the
clip of fasteners 81 away from the item to be fastened (i.e., the
mattress assembly).
[0058] In other embodiments, the systems and methods described
herein maybe used with two sided mattresses as well as mattresses
that are capable of being used with adjustable beds. For example, a
mattress for an adjustable bed may have a foam edge that has a
break or a flexible component that is disposed somewhat midway
along both long edges of the mattress. In this way, the adjustable
bed will be more capable of pivoting around a central axis as the
flexible portion built in the foam edge readily allows the mattress
to pivot and bend.
[0059] It will be understood that any innerspring unit may be
employed with the systems and methods described herein. Thus, open
coils, pocketed coils, coils in foam, and even all foam units,
which may include sections of different firmness, maybe used with
the methods described herein.
[0060] The embodiments shown of the present invention are intended
to be merely exemplary and those skilled in the art shall be able
to make numerous variations and modifications to them without
departing from the spirit of the present invention. All such
variations and modifications are intended to be within the scope of
the present invention as defined in the appended claims.
[0061] For example, the disclosed invention may be used to
assembled foam encasements using other types of fasteners.
According to other implementations, the invention may be employed
assembled using alternative types of dispensers, other than
explicitly disclosed.
[0062] The order in which the steps of the present method are
performed is purely illustrative in nature. In fact, the steps can
be performed in any order or in parallel, unless otherwise
indicated by the present disclosure.
* * * * *