US2224300A - Mattress and method of manufacturing the same - Google Patents

Description

Dec. 10, 1. J. R. JOHNSON. 2,224,300

MATTRESS AND METHOD OF MANUFACTURING THE SAME Filed May 27, 1938' 2 Sh ets-Sheet 1 Deco 1940- Y J. R. JOHNSON 2 MATTRESS AND METHOD OF MANUFACTURING THE SAME Filed May 2'7, 1938 2 Sheets-Sheet 2 INVENTQR, 2 m 72m BY M M2hw ATTORNEY.

Patented Dec. 10, 1940 UNITED STATES PATENT OFFICE MATTRESS AND METHOD OF MANU- FACTURING THE SAME Application lllay 27, 1938, Serial No. 210,327

2 Claims.

My invention relates to a mattress embodying a presewed and partially closed easing, into which a resilient core is slid or inserted, after which the casing is closed.

Objects of my invention are to fasten or anchor the core to the casing so as to prevent their relative shifting or disarrangement; to do this by the use of means which are concealed when the casing is finally closed; to employ for anchoring means flexible elements which will accommodate themselves to the movements of the mattress when in use, without injury to its component parts; to enable the assembly and anchoring of the core and casing to be readily accomplished by unskilledlabor; to produce a cored mattress which is easily assembled, simple in construction and moderate in cost; and to secure the other benefits and advantages hereinafter pointed out and claimed.

In the drawings Fig. 1 is a perspective view, on a reduced scale, of a typical mattress, with one end seam partially unclosed; Fig. 2 is a cross sectional view taken as on line 2--2 of Fig. 3; Fig. 3 is a plan view, with the top of the casing removed, the figure being shortened by excission of medial portions, and the spring arrangement of the core, which is conventional, being shown diagrammatically in Fig. 2 and in most of the figure, but more in detail in the upper left hand corner; Fig. 4 is a view on an enlarged scaleof a section of an open end of the mattress showing the anchoring means from both top and bottom, gathered and knotted together; Fig. 5 is a similar end view, also on an enlarged scale, but showing a modification in securing the ends of the anchoring elements to each other; Fig. 6 is a cross sectional view of a modified form of my invention, the right hand edge seams being unclosed; Fig. '7 is a longitudinal edge view on a relatively reduced scale, taken as looking from the right on Fig. 6; and Fig. 8 is an illustration of a tool suitable for use in assembling the mattress.

In all the figures similar parts are designated by similar reference numerals.

In the art of mattress making a system has been developed of making a presewed case, closed, except to an extent which will permit the insertion of an elastic core through one end, after which the casing is completely closed. This has been found advantageous in shipping the casings and the cores knocked down and not assembled, thus permitting the final assembly to be made by local distributors, who may vary the design of the casing used with the core to meet the tastes of purchasers. This system has proven quite satisfactory in the marketing of such mattresses. However, it results'in the core being free and not attached nor anchored to the casing which may shift, slip, or slide more or less, particularly laterally around the core. Such mattresses are usually finished with rolled edges; and it is desirable to have those edges retain their proper positions during the use of the mattress; for their displacement results in their forming ridges in improper positions on the mattress, which are both unsightly and uncomfortable to the users. Thus, if a person sits on the rolled edge of a mattress, the tendency is to push that edge outward and downward, so that it may not cooperate properly with the adjacent edge of the core, resulting in undue wear of the core edge against the casing, and a more or less unsatisfactory functioning of the casing and the core in relation to each other.

As already mentioned it is desirable to avoid tufting through the casing and the core to anchor them to each other, to avoid which, I proceed as follows:

A conventional core I of interconnected coiled springs. 2, 2 assembled within resilient bordering wires 3 is preferably employed. Panels 5, 5 are combined with boxing 6 to form the mattress casing, into which the core I is slid, preferably through an unclosed end of the casing. Stout tapes or bands 1, l are fastened at one end into the seams of the casing, and the tapes are then led into the interior of the casing and carried around and through coils of the springs 2, -2 toward the outer end of the core. These tapes are preferably attached to the casing at a point toward its inner end which is beyond the normal reach of a workman inserting his arm through the open end of the casing; so that provision must be made for threading the tapes properly around and through the springs. This may be done by running the ends of the tapes through the springs as the core is slid into the casing and carrying the ends, which are sufiiciently long for the purpose, through the springs as the core is slid into place. It may also be accomplished by the use of suitable tools 8, such as illustrated in Fig. 8, two of which may be slid in between the wires of the core, before the core is incased, along lines on which it is desired to have the tapes drawn out, and the free ends of both tapes on each side carried through the adjacent hooks 9 on the ends of the tools over which a keeper [0 may be slid home, as shown in broken lines in Fig. 8, so that, at the proper time, the tools may be withdrawn without snarling in the springs. Alternatively, if the tapes are not threaded through the hooks on the tools as the core is inserted, the shank of the tool 8, which has been positioned approximately in the desired path of the tape, may be slid inward so as to free the hook 9 from the keeper l0, and to allow it to engage the loose tapes, and then be drawn forward at the proper time to carry the tape out between the springs.

In this way four tapes secured toward the inner end of the casing are extended outward to the outer end of the core.

Another series of four tapes, H, H, are attached to the inside of the casing toward the front end of the mattress, and may be led around and through the springs on desired paths, as the core is slid into the casing, or afterwards, as these tapes II, I I can be readily reached by the hands of the operative inserted through the open end. of the case. The tapes I and II are then drawn tight, so as to hold the rolled side edges of the casing close to the core, the rolled edges registering properly with the wire edges of the core.

The tapes I and H are preferably wound or tied firmly around one or more of the springs 2, 2, for instance as shown in the lower left hand corner of Fig. 3, the tapes being then threaded through the coilsof adjacent springs to a central position where-the ends of all eight tapes may be tied or otherwise fastened to each other, for instance as shown at 12, in Figs. 3 and 4, or optionally the ends of four tapes on one side of the mattress may be tied or fastened to each other, and the ends of the four tapes on the other side of the mattress may be similarly connected. And, if desired, the tapes may be fastened to the ends of coiled springs l3, 13, as shown in Fig. 5, and drawn taut, so that the springs may take up slackness developing in the tapes in use, and will keep them fairly taut, thus supplementing the action of the springs through which the tapes are threaded and secured, in such a way as to cause the springs to exert continuous tension on the tapes. If desired the ends of the tapes may be secured to each other by sewing, or by connecting them otherwise than by tying.

In Figs. 6 and 7 I have illustrated a modification of my invention wherein tapes I 6, l6 are fastened at one end into the rolled edge seam of the casing, and, after the core has been slid into the casing, are drawn through the springs, under the edge wires of the core and out through openings left in the opposite edge seam. These tapes may then be drawn tight, and sewed or fastened into the edge seam, the free ends of the rolled edge tapes I1, I! being then sewed in place around the edge seam to complete the closure of the casing.

By this arrangement it will be seen that four tapes may be passed from one edge to the other of the mattress, running under the edge wires and through the ends of the coiled springs so as to efiectually tie the core to the casing.

I wish it to be distinctly understood that the number of the tapes used, and the points at which they are attached to the casing and to the springs and to each other may 'be varied as may be found desirable.

The paths of the tapes through the springs, as illustrated, are to be considered simply as typical and by no means exclusive, although it is desirable to have the tapes so associated with the springs that the springs keep the tapes under tension when the assembly is completed. Other details of construction may be modified as by the use of mechanical equivalents without departing from the spirit of my invention or the scope of my claims.

Having thus described my invention what I claim and desire to secure by Letters Patent of the United States is:

1. A mattress embodying a unitary, presewed double faced casing, having complete top, bottom and boxing elements, a completely preassembled core, embodying coiled springs, freely inserted in the casing, and means consisting of a textile tape having a portion fixedly attached to and within the casing at one side thereof and interlaced with springs of the core longitudinally and transversely thereof, and another tape similarly attached to and within the opposite side of the casing and similarly interlaced with a plurality of core springs, the

free ends of said tapes being fastened to each other to anchor the core in the casing, the anchoring means being wholly concealed and inaccessible from without when the casing is completely closed.

2. A mattress embodying a unitary, presewed double faced casing, having complete top, bottom and boxing elements, a completely preassembled core, embodying coiled springs, freely inserted in the casing, and means consisting of r a textile tape having a portion fixedly attached to and Within the casing at one side thereof and interlaced with springs of the core longitudinally and transversely thereof, and another tape similarly attached to and within the opposite side of the casing and similarly interlaced with a plurality of core springs, and a second pair of textile tapes similarly attached but at points nearer one end of the casing, and similarly interlaced with the springs, the free ends of all the tapes being fastened together to anchor the core in the casing, the anchoring means being wholly concealed and inaccessible from without when the casing is completely closed.

JAMES REID JOHNSON.

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