Knitted Mattress Cover, Mattress and Method for Manufacturing a Knitted Mattress Cover

Abstract

The present invention relates to a mattress cover, and more in particular a knitted mattress cover, comprising: a top panel, at least one side panel, and at least one tape edge connecting the top panel with the at least one side panel, wherein the top panel, the at least one side panel and the at least one tape edge are integrated into a seamless, one-piece knit. The invention further relates to mattress comprising such a mattress cover and a method for manufacturing a knitted mattress cover according to the invention.

Description

BACKGROUND OF THE INVENTIONField of the Invention[0001]The present invention relates to a mattress cover, and more in particular a knitted mattress cover. The invention further relates to mattress comprising such a mattress cover and a method for manufacturing a knitted mattress cover according to the invention.Description of Related Art[0002]Commonly known mattress covers are composed of plurality of components such as panels, borders, gussets and tape edges. During the manufacturing of such mattress covers, these components need to be cut to their required size and need to undergo several sewing operations for the hemming of the edges. Moreover, additional sewing operations are needed to join these individual components together to form the finished mattress cover. All of the above manufacturing steps are labour intensive and often require additional, costly equipment. Moreover, to meet certain market demands, mattress covers are commonly provided with additional product features ...

AI Technical Summary

Benefits of technology

[0008]It is also possible that the mattress cover comprises a knitted design element, more specifically a pattern and/or a logo, which forms an integral part of the mattress cover. Patterns commonly used on mattresses are patterns that give the mattress or parts thereof a quilted look. As the patterns is an integral part of the mattress cover, an appearance is achieved that is (nearly) identical to traditionally quilted covers without the necessity of performing an extra production step involving a quilting machine. A similar reduction in labour costs may be achieved with the incorporation of labels (e.g. to depict company logo's or emblems) that are directly knitted into the cover fabric and form an integral part of the mattress cover over the incorporation of labels that are for example sewn in or embroidered into the cover fabric.

[0009]The invention also relates to a mattress comprising a core having a top and at least one side, which top and at least one side are least partly encased by a knitted mattress cover according to the invention. In an embodiment of the mattress, the mattress cover fully encloses the top and sides of the core. Herewith a full wrap cover is created that at least encloses the top and sides of the mattress and eliminates the need for additional top or side panels to be sewn or otherwise connected to the mattress cover. In addition, it is possible that the mattress comprises a bottom side covered by a non-woven fabric. The non-woven fabric hereby forms a durable, cost-effective and lightweight backing material.

[0010]The invention further relates to a method for manufacturing a knitted mattress cover comprising integrally knitting a top panel, at least one side panel and at least one tape edge to form a one-piece cover. With this method, the several component that make up the mattress cover are manufactured and integrated into a one-piece cover with a single knitting operation. This significantly simplifies the process for manufacturing a mattress cover compared to commonly used processes, thus increasing production rates and decreasing production (labour) costs. Moreover, the fact that the mattress cover is knitted provides the mattress cover an inherent elasticity that allows ...

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