Mattress design
View Patent ↗A mattress embodying a foam encasement surrounding individually wrapped coils and lacking a barrier separating upholstery layers from the coil assembly. Border material is affixed to sidewalls forming the foam encasement and the upholstery layer is tacked to a base of the foam encasement.
1. A mattress, comprising:
a foam encasement, the foam encasement including a perimeter, a base and a plurality of sidewalls each having a height and a top surface, the sidewalls defining in an interior of the foam encasement;
an innerspring unit including a plurality of springs contained within the interior of the foam encasement, wherein each of the springs extends vertically from the base for a distance equal to the height of the sidewalls; and
an upholstery assembly layer, the upholstery assembly layer extending across the top surface of each of the sidewalls; and
a fabric border extending about the perimeter of the foam encasement, the fabric border including an inner layer which is affixed to the top surface of the sidewall, wherein the upholstery assembly layer includes a quilted panel and the fabric border includes an upper terminal end portion, the quilted panel being attached to the upper terminal end portion of the fabric border.
2. The mattress of claim 1 , further comprising a plurality of fasteners attaching the quilted panel to the base of the foam encasement.
3. The mattress of claim 2 , wherein the fabric border includes a lower portion and an upper portion, the upper portion extending vertically beyond the top surface of the sidewalls.
4. The mattress of claim 3 , wherein each of the springs of the innerspring unit is individually wrapped in a sleeve and each sleeve of the individually wrapped springs is attached to at least one adjacent sleeve.
5. The mattress of claim 4 , wherein the mattress includes a top sleeping surface and a bottom surface, the bottom surface lacking an upholstery assembly layer overlaying the plurality of springs.
6. The mattress of claim 5 , wherein the springs do not extend within the sidewalls of the foam encasement.