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Патент USA US2105224

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Jan. 11, 1938.
G. OLSON
2,105,224
MATTRESS AND METHOD OF MAKING
Filed NOV. 6, 1933
I 927202‘
4145A???’ 0450”
%w.’
Jttarnqy
Patented Jan. 11, 1938' '
2,105,224
UNITED STATES PATENT OFFICE
2,1053%
MATTRESS AND METHOD OF MAKING
Gilbert Olson, Minneapolis, Minn, assignm- w
Sanitary Mattress Company, Minneapolis,
Minn., a corporation of Minnesota
Application November 6, 1933, Serial No. 696,850
l'lCla-lms. (CL 5-351)
This invention relates to a mattress and meth
od of making the same, and particularly to a
mattress of the type comprising a spring struc
ture or spring unit together with suitable padding
5 or stuffing material, such as felt, cotton, hair or
the
like.
-
.
'
'
springs l0. These springs are suitably connect~
‘ed in a unit in a manner well known in the art
and which need not be further described. Said
spring unit is covered with a coarse woven or light
weight fabric ll which extends around the sides
or over the top and bottom of the spring unit or
In constructing a mattress it has been the com _ both. In the present method of making the mat
mon practice of recent years to form an edge roll, tress the spring unit comprising the parts Ill and
located substantially at the top and bottom cor
ll is placed on a table and the boxing I! placed
1 O ners of the mattress or at the top and bottom of.
around said unit, the ends of the boxing (not
. the side portions thereof. These edge rolls in a > shown) being sewed together. The boxing I2 is
great many cases have been formed by placing of novel construction and comprises an outer
ties or stitches through the top and sides of the layer of fabric l2a which forms the outer side of
mattress. It is desirable to have the top and bot
' tom of the mattress or the covers for the ?at sides
of the mattress unbroken. It is, however, at the
same time desirable to have the edge roll con
the mattress when completed and will be of the
desired material for this purpose. In some mat
tresses this fabric is of various kinds of ticking,v
while in other mattresses it is made of various
struction to give the mattress the desired shape. ' grades of damask and other similar material. '
It is an object of this invention, therefore, to
20 provide a simple, novel and improved method of
forming a mattress so that a very e?icient edge
roll construction is provided and at the same time
. the top and bottom covers of the mattress are
plain and have no stitching therethrough inside
of their edges.
It‘is a further object of the invention to pro
vide a novel and improved form of boxing for a
mattress.
-
>
It is still another object to provide a novel and
30
economical method of forming the mattress.
. It is also an object of the invention to provide
a very simple and economical mattress and one
which has a very pleasing appearance and is very
effective for‘ comfort and durability.
' _- These and other objects and advantages of the
invention will be fully set forth in the following
description made in connection with the accom
' panying drawing, in which like reference char
acters refer to similar parts throughout the sev
40 eral views and in which:-—
.
_
Fig. 1 is a plan view showing the mattress at
an intermediate stage;
'
Fig. 2 is a vertical section taken substantially
on line 2-2 of Fig. 1;
45
' ‘
Fig. 3 is a vertical section similar to Fig. 2 show
-ing a further step in the making of the mattress;
Fig. 4 is a horizontal section taken substantial
ly on line 4-4 oiFig. 2;
v
'
Fig. 5 is a partial vertical section similar to
50 Figs; 2 and 3 showing the completed mattress;
and
I
Fig. 6 is a vertical section of a partially com
ted‘mattress showing a modi?cation.
A layer of ?lling or padding, l2b such as cotton,
felt, hair or similar ?lling material used in mat 20
tresses, is placed over the layer l2a and a layer
of lining material l2c is placed on top of the
?lling lib opposite the layer l2a. The ends of ‘
the lining I20 and the ?lling l2b are then bent
reversely or folded inwardly or outwardly at the
inside of layer l2a. Ties such as staples, rivets,
stitches, or as shown eyelets l3 are then inserted
or placed through the inner side oflining lie,
the outer layer I21: and the folded in end portion
. of layer l2c.
As shown there are three rows of ‘ 30
eyelets, the center row passing only through the
?lling, inner layer I20 and the outer layer I211.
The outer rows pass through the inner layer l2c,
the outer layer I'Za and the folded in edge por
tion of layer l2c which is in contact with outer 35
layer lIa. Folding the ?lling lib at the ends of
the boxing forms the enlargements or roll por
tions lid. When the boxing, which is separate
ly formed, has been placed around the spring unit
Ill and ll as above described, said boxing is se
curedto said spring unit by spaced stitches it
which‘ extend through the lining layer lie and
the covering ll of the spring unit, these stitches,
however, not engaging the springs Hi.
When the >
boxing has been so placed and connected to the 45
spring unit cover, a heavy layer of padding or ?ll
mg I! is placed on top of the spring unit and a
layer It of lining material, usually muslin, is
placed over the padding It. This lining layer
has been previously cut to be of the proper size 50
and after it is placed on padding I! the edges
thereof are brought into alinement with the edges
of the outer layer l2a of the boxing and the two
Referring to the drawing, a mattress is shown ' edges arev held together at widely spaced points by
55 comprising a spring unit containing the coiled suitable quickly operable means such as the spring
2
9,100,924
clips ll. It is not necessary to use many of the
clips l1, these being placed two feet or more apart.
The mattress as thus far constructed is taken to
the sewing machine and the edge of the outer
layer 12a of the boxing and the edge of the lining
l6 are connected by the seam or the stitching I8.
While any kind of a sewing machine may be used,
. or the mattress sewed by hand if desired, in prac
tice the mattress is preferably taken to a machine
10 having a table and a sewing machine mounted
thereon which travels about the mattress. The
seam i8 can thus be very rapidly made. Obvi
ously instead of sewing said edges together they
could be fastened together with pins or clips
15 placed close together.
The mattress is now turned over to rest on
the lining I6 and padding l9 similar to the pad
ding I8 is placed on the other side of the spring
unit. Another layer of lining 20 is placed over
20 the padding l8 and the edge of this lining is
clipped at spaced points to the other edge of the
boxing layer |2a as shown in Fig. 2. The mat
tress is now again taken to the sewing machine
- and the edges of lining 20 and the edge of the
25 boxing layer |2d ‘sewed together by the seam 2|.
If desired the padding l5 and the padding I8
may be placed on opposite sides of the spring
unit and both lining layers i6 and 20 placed in
position and clipped by the clips l'l before the
80 seams I8 and 2| are put in.
With the mattress in the condition described,
stitches or ties are now inserted to form an edge
roll. While any instrument or machine can be
_used to do this, one way in which it has been
done is by the use of a long sewing needle 22.
This needle is 'passed through the mattress sub
stantially in the position shown in Fig. 3 with a
sewing thread or cord 28 threaded therein or
placed through the eye thereof. The needle is
pushed through the mattress from the boxing
side and passes through the lining layers i8 and
28. The needle is passed through until the eye
thereof and the thread therein is some distance
inside of the boxing and disposed in the packing
45 or stuffing l5 and l9.v The needle is then moved
slightly laterally and again passed out through
the boxing.
Ties or stitches 24 are thus formed
and these extend through the boxing and catch
some of the padding which is pulled down close
50 to the inner side of the boxing.
55
60
'
70
75
The stitches or
ties 24 are preferably made in line vertically with
the eyelets l3. The stitches or ties 24 cause the
rolls |2d to be pulled inwardly so that they en
gage and overlie the corner of the spring unit.
These ties 24 thus act to form ?rm edge rolls
on the mattress. While the mattress is shown
with the thickened or folded over portions |2d
at the top and bottom of the boxing, it is ap
parent that an edge roll effect would be produced
with a-boxing without this extra thickness. The
ties or stitches 24 pull the outer layer l2a. in
ward so that it is substantially in a vertical
plane with the outer ends of the eyelets l8. A
desirable stiff and substantially vertical side wall
is produced on the mattress, giving a pleasing
appearance and insuring that the mattress will
be retained in proper shape. While the stitches
24 are shown as engaging and holding quite a
little of the ?lling or padding | 5 and I8, it is
apparent that much the same effect would be
produced if the stitches 24 were taken only
through the boxing and no appreciable amount
of the padding caught in the stitches.
After the stitches 24 have been inserted all
around the mattress, the seams I8 and 2|, or
other fastening means used are opened or re
moved and the lining layers I8 and 28 removed.
A top cover 25 of the mattress and the corre
sponding bottom cover are placed over the pad.
ding portions |I and I8 and then sewed to the
edge of the outer layer |2a of the boxing by
the seam or stitching 28, a tape 21 preferably
being folded over the edges through which said
stitches also pass” By removing the lining lay
ers l6 and “they may be repeatedly used in
the intermediate operations of making the mat
tress. These layers, however, do not necessarily
have to be removed and if made of light and
cheap material the outer covers may be placed
thereover and sewed to the layer |2 of the
boxing.
I
From the above description it is seen that ap
plicant has provided a simple, e?icient and eco
nomical way of constructing a mattress. The
edge rolls are of' de?nite form and effectively 20
placed in the mattress and yet they are con
tained on the inside of the outer covers. The
edge rolls overlie the corners of the spring unit
and thus tend to swing outwardly, thus ten
sioning the outer layers of the mattress and 25
holding the same in desirable form.
At the same
time the stitches 24 maintain the substantially
vertical wall on the boxing and give it a rigid
effect. As stated the stitches 24 are preferably
alined with the eyelets l8 as shown in Figs. 3 30
and 5, thus giving a. neat and finished appear-_
ance to the mattress.
inside of seam 28.
The cover 25 is not pierced
In Fig. 6, a slightly different form of boxing
is shown in which stitches 28 are used instead 35
of the eyelets l8. The outer layer 880. is provided
similar to layer |2a and is caught by all of the
stitches 28. An inner layer 80!) is provided over
lying the ?lling 88c and the filling and inner
layer 88b are folded at the ends and caught by
the stitches 28. This forms rolls 88d at the ends
and when the boxing is placed about a spring
unit 8| and secured thereto by stitches 32, the
rolls 8811 will overlie the corners of the spring
unit. The boxing 88 illustrates that either
stitching or eyelets can be used in the mattress
shown and described. In the boxing shown in
Fig. 6 the central stitches 28a. are the equiva
lent of the eyelets |8 in Figs. 1 to 5. The
stitches 28 adjacent the end rolls 88d are in a
sense the equivalent of the stitches 24. When
the boxing 88 has been positioned as shown in
Fig. 6, the padding or filling 88 is placed on the
spring unit 8| and the outer covers 34 can then
be placed over the padding and sewed directly
to the outer layer 880. of the boxing. A tape 85
preferably is folded over the edges of sheets 80a.
and 34. A mattress is thus formed in which
there are no stitches in the outer layers or cov
ers 84 inside of its edge seam and the outer cov
ers are not pierced at any time by a sewing nee
dle.or other instrument. At the same time an
edge roll is provided formed by the portions 80d
which is disposed within the outer cover. A very
shapely mattress is thus produced and it is pro 65
duced with very little labor, there being very
few steps in its production. It will be under
stood that the stitches cr seams 28 and 28a in
the boxing are made‘on the sewing machine be
fore the boxing is placed about the spring unit.
From the above description it will be seen that
applicant has provided a simple and e?icient
mattress, one that has an effective edge roll at its
comers and which edge roll is disposed with
in the outer cover. The outer cover as above 7‘
2,105,824
3
stated is not pierced by "any needle or instru- , tical plane and means independent of said outer
ment. In some of the better mattresses the covers engaging said enlarged portions of said
piercing of the outer cover is objectionable as ?lling and pulling and disposing the same in
the fabric is injured and the holes can be ob
wardly about said spring unit, said enlarged por- ~
served. ‘ As stated, the lining sheets used in the intermediate steps of the method can be removed .
and used repeatedly with di?erent mattresses.
The mattress has been'amply demonstrated in
actual practice, has been found to be very success
10 ful and e?icient and is being commercially made.
It will, of course, be understood that various
changes may be made in the form, details, ar
rangement and proportions of the device and in
the steps and sequence of steps of the method
.15 of making the same without departing from the
scope of applicant's invention, which, generally
stated,- consists in a method and product capable
of carrying out the objects above set forth, such
as disclosed and de?ned in the appended claims.
20
What is claimed is:1. A boxing for a mattress comprising an outer
layer of fabric, an inner layer of fabric, a‘?lling
between said layers, said inner layer being folded
at its sides toward said outer layer to enclose said
25 ?lling, said ?lling having an enlarged portion at
its sides adapted to form an edge roll and fasten
tions forming edge rolls for said mattress.
5. A mattress having in combination, a spring
unit, padding overlying said unit, a boxing ex
tending about the sides of said unit and having
an outer layer of fabric, aninner layer’ of fabric,
a ?lling between said layers, said inner layer be
ing folded towards said outer layer to enclose
said ?lling, said ?lling having enlarged portions
at the sides thereof, means for securing and
drawing said enlarged portion inwardly about the
corners of said spring unit to form edge rolls and 15
outer covers for said mattress having their edges
secured to the edges of said outer layer of said
boxing.
'
6. A mattress having in combination, a spring
unit, padding overlying said unit, a boxing sur
rounding said unit at the sides thereof compris
ing an outer layer of fabric, an-inner layer of
fabric, a ?lling between said layers having an
enlarged portion at its side, said inner layer of
fabric being folded toward said outer layer to 25
enclose said enlarged portion, an outer cover for
ing means extending through said layers andv said mattress permanently sewed at its edge to
?lling.
the edge of said outer layer of said boxing, means
2. A boxing for a mattress comprising an outer
30 layer of fabric, an inner layer of fabric, a ?lling
between said layers, said inner layer being folded
at its sides toward and into contact with said
outer layer to enclose said ?lling, fastening means
independent of said outer cover engaging said
enlarged portion of said ?lling for holding the 80
same inwardly about the corners of said spring
unit to form an edge roll, said outer cover thus
being unpierced inwardly of its connection to
extending through said layers and ?lling at the . said outer layer of said boxing and an outer cover
central portion of said boxing and fastening at the other side of said spring unit permanently
means spaced at either side of said last mentioned sewed at its edge to the other edge of said outer 35
fastening means extending through said inner
and outer layers and ?lling and also through the
40
folded over portion of said inner layer.
3. A mattress having in combination, a spring
unit, padding overlying said unit, a boxing sur
layer of said boxing.
-‘
,
7. A mattress having in combination, a spring
unit, padding overlying said unit at the top and
bottom thereof, a boxing extending about the 40
sides of said unit comprising an outer layer of
rounding said unit at the sides thereof compris- - fabric forming the outer side of the ?nished
ing an outer layer‘ of fabric and a layer of ?lling,
‘said latter layer having an enlarged portion at its
45 side, an outer cover for said mattress permanently
sewed-to the edge of said outer layer of said box
ing, stitches independent of said outer cover en
gaging said enlarged portion of said ?lling and
a portion of said mattress inwardly thereof and
50 securing and pulling said enlarged portion in
wardly about the corners of said spring unit to
form an edge roll, said edge roll thus being held
in position independently of said outer cover and '
an outer cover at the other side of said spring
55 unit having its edge sewed to the edge of said
outer layer of said boxing said outer layer of
fabric of said boxing in the ?nished mattress be
ing disposed in a substantially vertical plane be
tween said outer covers and the outer side of said
60
enlarged portion being disposed substantially in
said plane.
.
4. ‘A mattress having in combination, a spring
unit, padding overlying said unit, a boxing ex
tending about the sides of said unit and having
an outer layer of fabric, an inner layer of fabric
and a ?lling between said layers, said ?lling ex
tending to each side of said boxing and being
folded to form an enlarged portion at each side
of said boxing, said enlarged portions being at the
70 outer side of the edges ofsaid padding, an outer
cover at each side of said mattress, said covers
having their edges respectively secured to the
edges of said outer layer of said boxing and being
unpierced within said outer edges, said ?lling in
said boxing being disposed in a substantially ver
mattress, an inner lining layer, ?lling between
said outer layer and inner lining layer, said ?ll
ing being reversely folded at‘ its sides to form
enlarged portions, said lining layer being folded
toward said outer layer to ‘enclose said enlarged
portion, fastening means extending through said
outer layer, lining layer and ?lling between said
enlarged portions, outer covers for said mattress 50
overlying said padding at either side thereof hav
ing their edges permanently connected to the
edges of said outer layer of said boxing, and
means engaging said enlarged portions but not
said outer covers for holding said enlarged por
tions inwardly over the corners of said spring
unit to form edge rolls, whereby said outer cov
ers are not pierced inwardly of their connection
to said outer layer of said boxing.
8. The method ofmaking a mattress which con 60
sists in providing a boxing having an outer layer
of fabric and a layer of‘?lling, placing said box
ing around the sides of a spring unit, placing
padding on said unit, placing a lining sheet over
said padding, securing the edge of said lining
sheet to the edge of said outer layer of said box
ing to hold said parts in proper relation, stitch
ing through said boxing and the ?lling thereof
at its outer portion to draw said ?lling‘ inwardly
over the corner of said spring unit to form an edge 70
roll, limiting said stitching so that the stitches
do not pass through said lining sheet, removing
said lining sheet, then placing a top covering on
said ‘mattress and stitching the same to the outer
layer of said boxing, placing a bottom cover on 75
4
boxing.
of said" boxing, said last mentioned means being
independent and separate from said outer covers,
whereby said outer covers are not pierced in
9. The method of making a mattress which
consists in providing a spring unit, forming a
boxing having an outer layer of fabric, an inner
layer of fabric and a layer of ?lling between said
13. A mattress having in combination, a spring
unit, padding overlying said unit, a boxing sur
the other side of said unit and securing its edge
to‘ the other edge of said outer layer of said
‘fouter and inner layers, placing said boxing around
the sides of said unit, placing a layer of padding
10 on said unit, placing a lining sheet over said
padding, securing the edge of said lining sheet to
the edge of said outer layer of said boxing at
spaced intervals thereabout, stitching through
said boxing adjacent the side thereof to draw the
15 same inwardly over the corners of said unit to
form an edge roll, limiting said stitching so that
it does not pass through said lining sheet, remov
ing said lining sheet, placing a top cover over
said padding and permanently stitching the same
20 to the edge of said outer layer of said boxing,
whereby said top cover is not pierced inwardly
of its connection to said outer layer of said box
ing, placing a cover on the other side of said
spring unit and connecting the same to the other
25 edge of said outer layer of said boxing.
10. The method of.maklng a mattress which
consists in providing a spring unit, forming a
boxing having inner and outer layers of fabric
with a ?lling therebetween, said filling having an
wardly of their connection to the outer layers of
said boxing.
rounding said unit at the sides thereof compris- .
ing an outer layer of fabric and a layer of ?ll—
ing at the inner side thereof, said layer of ?lling
having an enlarged portion at its side, an outer
cover for said mattress permanently sewed to
the edge of said outer layer of fabric of said box
ing, stitches independent of said outer cover
engaging said enlarged portion of said ?lling
anchored in said padding, securing and pulling
said enlarged portion inwardly about the corners
of said spring unit to form an edge roll and an
outer cover at the other side of said spring unit
having itscdge sewed to the edge of said outer 20
layer of said boxing.
14. A boxing for a mattress comprising an
outer layer of fabric, an inner layer of fabric
and a ?lling layer of padding material between
said layers, said layer of ?lling being continuous 25
and folded to form an enlarged portion at its
sides and between said inner and outer layers of
fabric and fastening means extending ‘through _
said layers of fabric and ?lling.
15. A mattress having in combination, a spring "30
unit, padding overlying said unit, a boxing sur
said unit, placing a lining sheet over said pad
ding, connecting the edge of said lining sheet to rounding said unlt at the sides thereof compris
the edge of said outer layer of said boxing at ing an outer layer of fabric and a layer of ?ll
ing, said latter layer having an enlarged portion
spaced intervals thereabout, inserting ties to en
35
35 gage said enlarged portion of said boxing and at its side, the outer portion of said ?lling all
engaging said padding to draw said enlarged por ‘being substantially in the same vertical plane,
tion inwardly around the corners of said unit to an outer cover for said mattress permanently
form an edge roll, limiting said ties so they do sewed to the edge of said outer layer of said box—
not pass through said lining sheet, removing ing, means independent of said cover engaging
40
40 said lining sheet, placing a top cover on said said enlarged portion of said ?lling pulling the
padding and permanently stitching the edge of same inwardly and securing the same in posi
the same to the edge of the outer layer of said tion about the corners of said spring unit to form
boxing, whereby said outer cover is not pierced an edge roll and an outer cover at the other side
inwardly of its connection to the outer layer of of said spring unit having its edge secured to
45 said boxing, placing a cover on the other side of the edge of said outer layer of said boxing, said
said spring unit and connecting the same at its outer layer of said boxing in the ?nished mat
edges to the other edge of said outer layer of tress being ina substantially vertical plane be
tween said outer covers.
,
said boxing.
11. A boxing for a mattress comprising an
16. A mattress having in combination, a
50
50 outer layer of fabric, an inner layer of fabric, av spring unit, padding overlying said spring unit
?lling between said layers, means extending at top and bottom, a boxing surrounding the
sides of said spring unit comprising an outer
through said layers and ?lling adjacent the cen
tral part of said boxing securing said layers and layer of fabric and a layer of ?lling within said
30 enlarged portion at its side, placing padding on
?lling together, said ?lling being reversely folded
. at its sides to form enlarged portions, said inner
layer being folded toward said outer layer to lie
along the inner side thereof and enclose said
enlarged portion and securing means extending
through said outer layer, said folded over por
60 tion of said inner layer, said ?lling and said in
ner layer to hold said parts together.
12. A mattress having in combination, a spring
unit vhaving a cover thereon, a boxing extending
about the sides of said unit comprising inner and
65 outer layers of fabric, a ?lling between said lay
ers, said ?lling having an enlarged portion at its
sides, the outer side of said ?lling including said
enlarged portion being disposed in one substan
tially vertical plane, a layer of padding at each
70 side of said spring unit, means extending through
said boxing to hold said enlarged portions thereof
inwardly about the corners of said spring unit
.. to form edge rolls, outer covers for said mattress
overlying said padding and having their edges
76 permanently sewed to the edge of said outer layer
outer layer, said layer of ?lling having enlarged
portions at its top and bottom- and said layer
of ?lling at its outer portion being substantially
in one vertical plane, outer covers for said mat
tress overlying said padding respectively at the
top and bottom thereof and having their edges
permanently secured respectively to the edges 60
of said outer layer of fabric of said boxing and
means engaging said enlarged portions of said
?lling pulling the same inwardly over said spring
unit, said enlarged portions forming edge rolls
and said outer covers being unpierced inwardly of 65
their line of connection to said outer layers of
said boxing.
17. A mattress having in combination, a spring
unit of box-like form including a cover, a boxing
extending about the sides of said unit compris 70
ing inner and outer layers of fabric and a con
tinuous layer of ?lling between said layers of
fabric, said ?lling being folded to form an en
larged portion at the sides of said boxing be
tween said layers of fabric, the outer side of said 75
mosses
boxing being disposed su‘iosientieiiy in one verw
ticai plane, means extending through said iey=
ers of fabric and ?lling securing the same We
gether, a layer of padding at each side of said
‘spring unit, stitches extending through said in~=
ner layer of fabric at said enlarged portion of said
boxing and through the cover of said spring unit
adjacent the corner of said unit for holding said
hoxi
in
siiaion, seid emerged. poi'iio
hem
mg disposed over the corners of said unit and
forming ee rolls in said mattress, outer soar
ers for said mettress overlying said it dine and
edge rolls and having their edges permentiv
secured to the
layer of fabric.
V
respectively of seid mites
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