US1959082A - Mattress and its manufacture - Google Patents

Description

May 15, 1934.

, 1930 2 SheetsfSheet 1 c. LOFMAN MATTRESS AND ITS MANUFACTURE Filed Dec.

"l QSv Il 1930 2 Sheets-Sheet 2 C. LOFMAN MATTRESS AND ITS MANUFACTURE Filed Dec.

May 15, 1934.

Patented May 15, 19.34

^ A.UNiTED STATES 1,959,082 iim'rrmiss AND Irs MANUFACTURE `Charles Lofman, Riverside, Ill., assignor to S'. Karpen & Bros., Chicago, lll., a corporation of West Virginia Application December 15, 1930, Serial No. 502,533 l 7 Claims. l (Cl. 5-360) This invention relates particularly to mattresses or the like, in which the filling within the mattress-casing comprises a body of springs suitably' connected together to afford 4an inner spring- 5 structure, and suitable loose lling material, such as hair, cotton or the like, which supplements the -spring-structure and completes the filling of the mattress.

'Ihe primary object isto provide an improved lo method of manufacture, which enables a superior product to be produced at a very moderate cost. A further object is the production of such improved product.

In accordance with the present invention, a suitable spring-structure, comprising ,a body of light upholstery springs suitably connected together, is provided; a pre-built border-boxing (preferably quilted and comprising inner and outer fabrics and interposed filling material) and marginal inner edge-rolls are then Ltied 'or' stitched to the marginal portion of the springstructure at the planes of the upper and lower surfaces thereof; loose, or felted filling or stumng material is then placed over the sides of the spring-structure and may be reected over the inner edge-rolls; and the upper and lower casingfabrics are then placed in position and sewedto the upper and lower marginal portions of the border-boxing, it being understood that these portions project above and below, respectively, the upper and lowersurfaces of the spring-structure. vThemethod thus stated renders it possible to provide the mattress, or cushion, with edge-rolls in an extremely simpleand effective manner. That is, one canin this manner producea haliroll edge which gives an exceedingly pleasing appearance and' effect, coupled with the highest utility.

The invention is illustrated in preferred em- '40 bodiments in the accompanying drawings, in

Which- Fig. 1 is a broken elevational view of one form cf quilted border-boxing; Fig. 2, a similar View of a slightlymodified form of border-boxing; Fig. 3, a vertical sectional view taken as indicatedat line 3 of Fig. 1; Fig. 4, a broken horizontal sectional View taken as indicated at line 4 of Fig. 1; Fig. 5, abroken elevational view of the improved mat.. tress employingthe border-boxing illustrated in Fig. 1; Fig. 6, a broken vertical sectional View of the mattress shown in Fig. 5; Fig. 7, Aa broken detailed sectional View showing a slight modification in the attachment oithe` inner edge-roll to the spring-structure and boxing; Fig. 8, a broken plan view of a modified form of mattress, in which the inner edge-roll is positioned somewhat differently than in the preceding structures; Fig. 9,

Ia broken vertical sectional view of the structure shown in Fig. 8, the'upper layer of filling and the upper casing-fabric being omitted;' Fig. 10, a broken elevational view of the mattress shown in 60, Fig. 8, it being noted that the border-boxing of -Fig. 2 is vhere employed; and Fig. 11, a brokenI elevational view showing the mattress constructed with still another modification of the borderboxing.

Inthe construction illustrated in Figs. I and 3J?, the mattress comprises a border-boxing A; a spring-structure B; inner edge-rolls C; ties 4or stitches D which unite the edge-rolls and the boxing to the spring-structure; layers of lling material E, which are placed over (above and below) the spring-structure after the border-boxing and edge-rolls have been secured to the marginal rows of springs of said structure; and horizontal casing-fabrics F constituting the upper and lower sheets of the casing.

The border-boxing A preferably is quilted in any suitable manner. Preferably, the boxing comprises an outer strip of casing fabric 1, an inner strip of muslin ,2, and an interposed layer 3 80 of filling, such as cotton.

In the illustration given in Figs. I and 3 6-, the quilting is effected by sewing the fabrics and interposed filling material together along the longitudinal lines 4at a distance of an inch more 85 or less from the edges, and also sewing the parts together by oval lines of stitching in the vertical plane, as indicated at 5, the ends or apices of the ovals meeting the longitudinal lines of stitches at the points 6.-

The spring-structure B may be formed in any suitable manner. Preferably, a body of light upholstery springs are set together in longitudinal and transverse rows and are suitably connected together. In the illustration given, a body of springs of the Marshall type is shown. In this type of spring-structure, the upholstery springs 7 are inclosed in fabric pockets, or fabric cells 8, and the springs are united Vtogether by ties, or

strings 9.

In forming a mattress in accordance with the present' invention, a workman takes a body of springs and stitches to one marginal portion of the spring-structure the boxingV A and an edgeroll C. The stitching is continud above the body of springs until the border has been secured to the spring-structure throughout the periphery thereof. The operation is repeated at the other corner of the spring-structure. In the illustration given, the ties D may be understood as stitchcompleted, the structure comprises the springstructure, the edge-rolls, and the border-boxing properly united together.

In the illustration given, a layer of cotton or the like 10 is placed adjacent the marginal row of springs before the border-boxing is applied.

'I 'he ties or stitchings D preferably extend wholly through the boxing and at the points where the stitching is exposed, the loops register with the apices of the ovals 5. That is, they register with the points 6, where the apices of the ovals register with the horizontal lines of stitchings 4.

After the boxing and edge-rolls have been applied to the spring-structure, the workman places the layer of lling material E upon the springstructure, places a fabric F thereover, and then, by means of a sewing machine, sews the edgeportion of the fabric F to the upper edge portion of the fabric 1 of the boxing, as indicated at 11. In forming the seam at 11, a binding tape 12 is preferably folded over the edges of the fabric and sewed into the seam.

Having-completed the mattress at one side, the

structure is reversed, the filling E is applied over the spring-structure, the other horizontal casingfabric F is applied and the fabrics are united at the corner seam 11.

'By reference to Fig. 3, it will now be understood that the effect of the method described is to produce at the border-boxing inwardly drawn lines 4 which extend completely about the mattress periphery, as indicated in Fig. 5. However, the upper and lower surfaces of the mattress are not drawn downwardly or inwardly near the edges, so that the result is to leave the upper and lower casing-fabrics substantially smooth near the margins, and simply rounded over to meet the seam 11, as indicated at 14. Thus, something approaching a pin-cushion effect and involving a half edge-roll effect is produced. The result isan exceedingly pleasing appearance, coupled with a luxurious edge effect for the mattress.

In Fig. 7, a method of applying the inner edgeroll C is shown in some detail. A thick strip of cotton, or a thick strip of curled hair (having cheese-cloth secured to it, if desired) is employed. This strip may be connected with the boxing and with the spring-structure by means of the ties D, as shown in Fig. 7. That is, the stitchings may pass through the central portion of the strip. and the strip may ultimately be lled, so as to form a row when the casing-fabrics are to be united at the corner seam of the mattress. It will be understood that the illustrations are more or less schematic, it being diilicult to reproduce the exact `structure after it has been completed. Moreover, the details may be varied.

In the modification shown in Figs. 2 and 8-10, the structure is similar to that already described, and parts are correspondingly designated, except vthat the modified border-boxing is designated A( and the modified edge-roll is designated C. In this construction, the quilting lof the border-boxing is similar to that already described, except that the oval ends of the vertical figures designated 52 are formed by vertical lines of stitching As illustrated in Figs. 8 and 9, the edge-rol C' comprises a roll of hair 15 attached to or inclosed in a strip of cheese-cloth 152. In this example, a portion of the roll is interposed between the spring-structure B and the border-boxing A. The parts are united by ties or stitchings D', as appears in Figs. 9 and 10.

In the modification shown in Fig. 11, the structure is substantially like the previously described constructions, and corresponding parts are correspondingly lettered. In this instance, the border-boxing is designated A2, being slightly modified. y

The edge-roll is designated C2. The boxing A2 is quilted by means of horizontal lines of stitching 4a and vertical lines of stitching 4b, thus producing rectangular vertical figures between the planes of the horizontal lines of stitching 4. The vertical lines of stitching produce rudimentary vertical flutings between the lines of horizontal stitching.

The roll C2 is shown as comprising a hair roll. The filling material above the spring-structure, designated E2, is shown as comprising inner and outer layers of cotton or kapok 16 and an intermediate layer of curled hair 17. An exceedingly luxurious effect and an extremely pleasing appearance is secured in this construction. The ties or stitches D2 connect the boxing A2 with the edge-roll C2 and with the spring-structure in the manner described with reference tothe previously described constructions.

In this instance, the short exposed loops of the ties D2 register with the intersections of the vertical lines of stitching 4b with the horizontal lines of stitchings 42.

From the description given, it will be understood that the improved method obviates the necessity of carrying the ties or stitches which form the edge-roll of the mattress through the layers of filling material above the springs and through the horizontal casing-fabric. The effect is to simplify the manufacture and improve the appearance.

The foregoing detailed description has been given for clearness of understanding only and no unnecessary limitations should be understood therefrom, but the appended claims should be construed as broadly as permissible in view of the prior art.

What I regard as new, and desire to secure by marginal rows of light gauge upholstery springs;

stitching an internal edge-roll and a quilted boxing to the marginal rows by a common stitching at the plane of one surface of the spring-structure, said stitching being adapted to give a halfroll edge effect at the boxing and the edge-portion of said boxing projecting a distance above said surface of the spring-structure; applying a layer of filling material over the spring-structure; and applying a casing-fabric over said layer and sewing its edge-portions to the corresponding edgeportion of the boxing.

2. 'I'he method of mattress manufacture specined in claim 1 .as carried out by introducing a portion of the edge-roll between the boxing and the marginal row of springs and simultaneously stitching the boxing and the edge-roll to the springs. 1

3. A method of manufacturing a mattress with roll-edge effect which comprises: forming a quilted border-boxing having horizontal lines of stitching some distance from its edges and having vertical stitched gures intersecting at their ends the horizontal lines of stitchings; stitching by a common stitching the pre-formed borderboxing and anedge-roll to the marginal rows of a body of coil springs serving as a mattress therein, said stitchings passing wholly through the border-boxing and registeringrat their exposed loops with the points of intersection between the vertical stitchings and the horizontal stitchings of the border-boxing; applying a layer of filling material over the springs; and applying a casing-fabric over said layer of material and sewing the edge-portions thereof to the edge-portions of the boxing.

4. In a mattress structure: a body of coiled springs adapted to serve as a mattress lling; a quilted, pre-built border-boxing adjacent the marginal rows of springs; internal edge-rolls atthe junctions between the border-boxing and the marginal rows of springs; and common ties connecting the border-boxing and the border rows of springs to the internal edge-rol1s, said ties adapted to give a half-edge roll effect to the border-boxing.

5. A structure as speciiied in claim 4, in combination with layers of lling material above and 3 below the body of springs and casing-fabrics over said layers and having their edge-portions sewed to the edges of the border-boxing, said casing Afabrics presenting smooth unbroken surfaces with '7. A method of manufacturing a mattress with half-roll-edge effect, which comprises: employing as a filling a spring-structure having marginal rows of light gauge upholstery springs; introducing an edge-roll having a portion thereof between the boxing and the marginal row of springs; simultaneously stitching said edge-roll and the boxing to the springs applying a layer of lling material over the spring-structure; and

applying a casing-fabric over said layer and sewing its edge-portions to the corresponding edge portion of the boxing.

CHARLES LOFMAN.

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