Method and System of Manufacturing A Mattress and Components Thereof

Abstract

A system ( 10 ) for manufacturing a mattress ( 300 ) comprises multiple modules or stations ( 12, 132, 188, 200 ) used to sew together multiple components into a casing ( 252 ). A spring or other core ( 270 ) is inserted into the casing ( 252 ) before a top ( 274 ) is secured to the casing ( 252 ) to complete the mattress ( 300 ). One or more flanges ( 261, 266 ) may be incorporated into the casing ( 252 ) for securing the core ( 270 ) inside the casing ( 252 ). The system ( 10 ) provides an operator flexibility to manufacture different types of mattress with minimal changes.

1 . A method of manufacturing a casing for use in the manufacture of a bedding or seating product, said method comprising:
 sewing a web of border material to a web of gusset material along a first seam;   sewing a first web of flange material to the web of gusset material along a second seam, the first web of flange material overlaying the web of gusset material while said second seam is being sewn;   sewing the first web of flange material and the web of gusset material along a longitudinally extending third seam spaced inwardly from the second seam;   ruffling the webs of flange and gusset material at predetermined positions to complete a border assembly web;   cutting the border assembly web to a predetermined length to create a border assembly piece;   sewing the ends of the border assembly piece together to create a border assembly loop; and   sewing a bottom panel to the border assembly loop.   
   
   
       2 . The method of  claim 1  further comprising inserting a second web of flange material between the border assembly loop and the bottom panel. 
   
   
       3 . The method of  claim 1  wherein sewing said first and second seams occurs at a first sewing station. 
   
   
       4 . The method of  claim 3  wherein sewing said third seam occurs at a second sewing station remote from the first sewing station. 
   
   
       5 . The method of  claim 4  wherein sewing the ends of the border assembly piece together occurs at a third sewing station remote from the first and second sewing stations. 
   
   
       6 . The method of  claim 5  wherein sewing a bottom panel to the border assembly loop occurs at a fourth sewing station remote from the first, second and third sewing stations. 
   
   
       7 . The method of  claim 1  further comprising applying tape over aligned edges of said webs of border and gusset material prior to sewing the first seam. 
   
   
       8 . The method of  claim 1  further comprising placing said web of gusset material on top of said web of border material, the unticked sides of the webs facing each other, prior to sewing the first seam. 
   
   
       9 . The method of  claim 1  wherein sewing the first seam occurs at a first sewing machine and sewing the second seam occurs at a second sewing machine. 
   
   
       10 . The method of  claim 9  wherein sewing the third seam occurs at a third sewing machine, the third sewing machine having a ruffler. 
   
   
       11 . The method of  claim 1  further comprising marking the web of border material at predetermined locations to aid in sewing the bottom panel to the border assembly loop. 
   
   
       12 . The method of  claim 1  further comprising using an encoder to aid in ruffling the webs of flange and gusset material at predetermined locations. 
   
   
       13 . The method of  claim 1  further comprising using an encoder to aid in creating a border assembly piece of a predetermined length. 
   
   
       14 . The method of  claim 4  further comprising using an encoder at the second sewing station to aid in ruffling the overlapped web of first flange material and web of gusset material at predetermined locations. 
   
   
       15 . The method of  claim 1  further comprising applying tape over aligned edges of said border assembly loop and bottom panel prior to sewing the bottom panel to the border assembly loop. 
   
   
       16 . A method of manufacturing a casing for use in the manufacture of a mattress, said method comprising:
 at a first sewing station:   sewing a first web of border material to a web of gusset material along a first seam using a first sewing head;   sewing a first web of flange material to the web of gusset material along a second seam using a second sewing head downstream of the first sewing head, the web of flange material overlaying the web of gusset material;   at a second sewing station remote from the first sewing station:   sewing the webs of flange and gusset material along a longitudinally extending third seam spaced inwardly from the second seam using a third sewing head;   ruffling the webs of flange and gusset material at predetermined positions to complete a border assembly web;   cutting the border assembly web to a predetermined length to create a border assembly piece;   at a third sewing station remote from the first and second sewing stations:   sewing the ends of the border assembly piece together along a fourth seam to create a border assembly loop using a fourth sewing head; and   at a fourth sewing station remote from the first and second sewing stations:   sewing a bottom panel to the border assembly loop along a fifth seam using a fifth sewing head.   
   
   
       17 . The method of  claim 16  further comprising inserting a second web of flange material between the border assembly loop and the bottom panel. 
   
   
       18 . The method of  claim 17  further comprising applying tape over aligned edges of said border assembly loop and bottom panel prior to sewing the fifth seam. 
   
   
       19 . The method of  claim 16  further comprising placing said web of gusset material on top of said web of border material, the unticked sides of the webs facing each other, prior to sewing the first seam. 
   
   
       20 . The method of  claim 15  wherein each of said webs of flange material is passed through a folder prior to being sewn.