Collapsible mattress border construction and method

A border assembly for a mattress or other bedding material, said assembly comprising:

• a first foam side rail having a top wall, a bottom wall, an outer side wall, an inner side wall, a mitered end wall, and a square end wall;
• a first foam end rail having a top wall, a bottom wall, an outer side wall, an inner side wall, a square end wall, and a mitered end wall, wherein said mitered end wall of said first foam end rail is pivotably attached to said mitered end wall of said first foam side rail, thereby forming a mitered corner joint;
• a second foam side rail having a top wall, a bottom wall, an outer side wall, an inner side wall, a mitered end wall, and a square end wall, wherein said square end wall is pivotably attached to a portion of said inner side wall of said first end rail, thereby forming a joint;
• and
• a second foam end rail having a top wall, a bottom wall, an outer side wall, an inner side wall, a square end wall, and a mitered end wall, wherein said mitered end wall of said second foam end rail is pivotably attached to said mitered end wall of said second foam side rail, thereby forming a mitered joint, and said square end wall of said second side rail is pivotably attached to a portion of said inner side wall of said second end rail, thereby forming a joint.

A method of preparing a collapsible border assembly for pre-assembly into a mattress construction, comprising:

• forming a mitered end wall on a first side rail by cutting said end wall at an angle of between about 30 to 60 degrees;
• forming a mitered end wall on a first end rail by cutting said end wall at an angle of about 30 to 60 degrees;
• forming a mitered end wall on a second side rail by cut-ting said end wall at an angle of about 30 to 60 degrees;
• forming a mitered end wall on a second end rail by cutting said end wall at an angle of about 30 to 60 degrees;
• pivotably attaching said first side rail to said first end rail at said respective mitered end walls, thereby forming a mitered corner joint;
• pivotably attaching said mitered end wall of said second end rail to said mitered end wall of said second side rail, thereby forming a mitered corner joint;
• pivotably attaching an end wall of the second side rail to a portion of an inner side wall of said first end rail, thereby forming a joint;
• and
• pivotably attaching an end wall of the first side rail to a portion of an inner side wall of said second end rail, thereby forming a joint,
• wherein the first end rail, first side rail, second end rail and second side rail together form the collapsible border assembly.

A mattress assembly kit having component parts capable of being assembled at the mattress manufacturer's site, the kit comprising the combination of:

• a mattress core section;
• a collapsible border assembly having first and second side rails pivotably attached to first and second end rails, wherein said first and second side and end rails define a center opening to accommodate the mattress core section;
• a top sheet for attaching to top walls of said first and second side rails and said first and second end rails;
• and
• a bottom sheet for attaching to bottom walls of said first and second side rails and said first and second end rails.

A method of making a mattress that incorporates a mattress border assembly, comprising:

• expanding said collapsible border assembly having first side rails and second side rails pivotably attached to first end rails and second end rails, wherein said side rails and end rails define a center opening;
• inserting a mattress core into said center opening, whereby said collapsible border assembly forms a perimeter frame around said mattress core;
• attaching a top sheet onto top walls of said side rails and end rails;
• attaching a bottom sheet onto bottom walls of said side rails and end rails;
• encasing said mattress core, said collapsible border assembly, and said top and bottom sheets with a fabric or casing.