# US 11,896,135 B2 · Mattress assembly, subassembly, or components thereof, and method of making same > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,896,135 B2 - Document ID: US11896135B2 - Status: Granted - Kind: B2 - Application number: 17/164,626 - Filed: 2021-02-01 - Published: 2022-01-06 - Granted: 2024-02-13 - Earliest claimed: 2020-07-01 - Applicants: Loc Van Nguyen - Inventors: Loc Van Nguyen - Web page: https://patentgrep.com/patent/US11896135B2 ## CPC - A47C 27/002: {Mattress or cushion tickings or covers} - A47C 27/003: {having edge welts or rolls} - A47C 27/056: {with different layers of foamed material} - A47C 27/15: consisting of two or more layers (A47C27/16 takes precedence) - A47C 31/105: {for mattresses} - A47C: CHAIRS; SOFAS; BEDS ## Abstract Described herein is a method of forming a mattress (and product thereof) including providing a cover-top panel compact that includes a top panel having one or more filler layers and a drape that is affixed to the top panel at a first margin. The method entails detaching the drape at a second margin and inverting the drape to engage a supporting core, thereby completing the mattress assembly. ## Claims ### Claim 1 A mattress assembly comprising: a cover assembly including a top panel having a panel bottom, a panel top, and a drape fixed to the top panel by a tape edge, wherein the tape edge is fixed about a perimeter of the top panel at a fixed margin of the top panel; a support core having a topside, an underside, and sidewalls therebetween, wherein the panel bottom of the cover assembly is positioned on the topside of the support core; and wherein the drape comprises a movable tape edge, wherein the drape is pivotable about the fixed margin between a first position wherein the drape and the movable tape edge are engaged above the panel top and a second position wherein the drape extends along the sidewalls of the support core and the movable tape edge is positioned about a perimeter of said support core. ### Claim 2 (depends on 1) The mattress assembly of claim 1, comprising: wherein the cover assembly comprises a plurality of filler layers secured within the top panel, wherein the top panel is a cushioned top panel; wherein the drape includes a skirt secured about the sidewalls of the support core; and wherein the drape further includes a cover extension extending from the skirt to at least partially cover an underside of the support core and secure, at least partly, the drape thereto, and wherein said cover extension includes two free sections mutually attachable to encase said support core within said cover assembly. ### Claim 3 (depends on 1) The mattress assembly of claim 1, wherein said fixed margin is affixed about a bottom perimeter of the top panel and pivotable thereabout to mutually engage said free sections above the top panel or about the support core, and wherein said skirt extends from said fixed margin and from said bottom perimeter. ### Claim 4 (depends on 3) The mattress assembly of claim 3, wherein said cover extension is secured beneath said support core; and wherein said drape is detachable at the free sections and pivotable about said tape edge to cover said tape edge. ### Claim 5 (depends on 4) The mattress assembly of claim 4, wherein said cover extension is secured beneath said support core to encase said support core within said cover assembly; and wherein said cover assembly further includes a fixed top tape edge about a top panel perimeter, said drape being detachable at said free sections and pivotable about said top panel to cover said fixed top tape edge and said tape edge. ### Claim 6 (depends on 5) The mattress assembly of claim 5, wherein said cover extension is zippered. ### Claim 7 (depends on 2) The mattress assembly of claim 2, wherein said cover extension includes a drape margin extended beyond the sidewalls of the support core and fitted adjacent the underside of the support core. ### Claim 8 (depends on 7) The mattress assembly of claim 7, wherein said cover extension includes an extended flap secured, beneath the underside of the support core, to sections of said drape margins to secure the cover extension beneath the support core underside and encase the support core. ### Claim 9 (depends on 8) The mattress assembly of claim 8, wherein said cover extension covers an entirety of said underside and is detachably fastenable. ### Claim 10 (depends on 2) The mattress assembly of claim 2, wherein said tape edge defines a margin interface of the skirt and an underside cover extension commonly joined with the skirt. ### Claim 11 (depends on 2) The mattress assembly of claim 2, wherein the tape edge is closed about edges of one or more layers of the top panel. ### Claim 12 (depends on 2) The mattress assembly of claim 2, wherein said drape is invertible between a first disposition wherein said drape receives said support core and a second disposition wherein said drape is extended about said top panel. ### Claim 13 (depends on 2) The mattress assembly of claim 2, wherein said drape is pivotable about the tape edge adjacent said top panel to extend about said top panel and is pivotable about said tape edge to extend about said support core. ### Claim 14 A method of forming a mattress comprising the steps of: providing a cover assembly including a top panel having one or more filler layers and a drape fixed to the top panel by a tape edge that is affixed about a perimeter of the top panel at a fixed margin of the top panel, wherein the drape comprises a movable tape edge, including pivoting at least two free sections of the drape about the fixed margin of the top panel and engaging the free sections thereabove, thereby detachably fixing the drape about the top panel; juxtaposing the cover assembly with a supporting core having a topside, an underside, and sidewalls therebetween; and detaching the free sections and extending the drape to integrate the supporting core with the cover assembly to form a mattress, wherein the movable tape edge is located above said top panel prior to said extending, wherein said extending includes detaching said free sections from above said top panel and pivoting said drape about said fixed margin to uncover said tape edge and positioning said movable tape edge about a perimeter of said supporting core. ### Claim 15 (depends on 14) The method of claim 14, wherein said extending includes fastening the drape to the supporting core; and wherein said drape includes a border skirt and said extending includes engaging the supporting core with the drape such that the border skirt wraps about the sidewalls of the supporting core. ### Claim 16 (depends on 14) The method of claim 14, wherein said extending includes encasing the supporting core with the drape. ### Claim 17 (depends on 16) The method of claim 16, wherein said encasing includes uniting the free sections of the drape to encase the supporting core. ### Claim 18 (depends on 17) The method of claim 17, wherein said uniting includes zipping said free sections together. ### Claim 19 (depends on 14) The method of claim 14, wherein said extending includes detaching the free sections of the drape and extending the free sections proximately about the supporting core. ### Claim 20 (depends on 19) The method of claim 19, wherein said drape has a fabric extending from the fixed margin and said fabric includes free margins detachably fastened to the top panel, said extending including detaching the free margins from the top panel. ### Claim 21 (depends on 20) The method of claim 20, said extending including attaching, after said detaching, the free margins about the supporting core. ### Claim 22 (depends on 20) The method of claim 20, said extending including re-attaching, after said detaching, the free margins beneath the supporting core, including pivoting said free sections relative to the top panel and beneath and about the supporting core placed adjacent the cover assembly. ### Claim 23 (depends on 22) The method of claim 22, wherein, with said re-attaching, said cover assembly encases the supporting core. ### Claim 24 (depends on 16) The method of claim 16, wherein said drape includes a border skirt for fitting about the sidewalls of the supporting core and a cover extending outward from the border skirt at the tape edge, said extending further including pivoting said cover at said tape edge to extend over the underside of the supporting core and urge said border skirt about said sidewalls. ### Claim 25 (depends on 14) The method of claim 14, wherein said fixed margin is affixed about a bottom perimeter of the top panel and said drape includes a border skirt that extends from said fixed margin and from said bottom perimeter and wherein said providing is preceded by pivoting said drape about said fixed margin to mutually attach said free sections above the top panel; and wherein said top panel has a panel top and a panel bottom including said bottom perimeter, and said juxtaposing includes placing said panel bottom adjacent a top side of the supporting core; and wherein said extending further includes pivoting said drape about said fixed margin to extend the drape below the top panel and then attaching said free sections beneath the supporting core. ### Claim 26 (depends on 25) The method of claim 25, wherein said drape further includes a cover extension such that upon said extending, said border skirt extends relative to the top panel to at least partially cover an underside of the supporting core and secure, at least partly, the drape, and wherein said two free sections mutually attach to encase said supporting core within said cover assembly. ### Claim 27 (depends on 26) The method of claim 26, wherein said pivoting includes pivoting said drape about said tape edge to cover said tape edge. ### Claim 28 (depends on 27) The method of claim 27, wherein said cover assembly further includes a top tape edge fixed about a top panel perimeter, wherein said extending includes detaching said free sections and pivoting said drape about said fixed margin to uncover said top tape edge and said tape edge and uncover and locate said movable tape edge about a bottom perimeter of said supporting core, wherein the cover extension extends from said movable tape edge. ### Claim 29 A method of forming a mattress comprising the steps of: providing a cover assembly including a top panel and a drape fixed to the top panel by a tape edge, wherein the tape edge is fixed about a perimeter of the top panel at a fixed margin of the top panel, wherein the drape comprises a movable tape edge, including pivoting the drape about the fixed margin of the top panel and engaging the drape thereabove, thereby detachably fixing the drape about the top panel; juxtaposing the cover assembly with a supporting core having a topside, an underside, and sidewalls therebetween; and detaching and extending the drape to integrate the supporting core with the cover assembly to form a mattress, wherein the movable tape edge is located above said top panel prior to said extending, wherein said extending includes detaching said drape from above said top panel and pivoting said drape about said fixed margin to uncover said tape edge and positioning said movable tape edge about a perimeter of said supporting core. ### Claim 30 An unassembled mattress system comprising: a support core having a topside, an underside, and sidewalls therebetween; a cover assembly including a top panel having a panel bottom, a panel top, and a drape fixed to the top panel by a tape edge, wherein the tape edge is fixed about a perimeter of the top panel at a fixed margin of the top panel; wherein the panel bottom of the cover assembly is alignable with the topside of the support; and wherein the drape comprises a movable tape edge, wherein the drape is pivotable about the fixed margin between a first position wherein the drape and the movable tape edge are engaged above the panel top and a second position wherein the drape is extended to secure about the sidewalls of the support core and the movable tape edge is positionable to be secured about a perimeter of said support core.