Quilted border loop sidewall panel for bed mattress or foundation and method of making same

A method of making multiple quilted border loop sidewall panels of material for bed mattresses or foundations in different sizes, wherein plural layers of material are fed from one or more rolls through a programmable multi-needle quilting machine in registry with each other and are pressed and stitched together to form a quilted material, said plural layers of material being controllably moveable laterally with respect to a material feed direction and at least one needle bar-mounted needle of the machine in order to form, during stitching, stitch pattern elements which extend in both the material feed direction and laterally thereto, said method comprising:

• executing on a controller of the multi-needle quilting machine a first program to stitch one or more lines of stitching following a first programmed stitch pattern, said first programmed stitch pattern having a repeat length set equal to or greater than a length of a side or end of a first said mattress or foundation of a first size, wherein said first programmed stitch pattern includes a first prime pattern comprising plural said stitch pattern elements arranged to provide aperiodic pattern element variation along its length, which length is equal to or greater than the length of the side or end of the first mattress or foundation;
• carrying out stitching of said plural layers of material on said multi-needle quilting machine in accordance with said first program, in order to form a quilted material comprising said prime pattern;
• executing on the controller of the multi-needle quilting machine a second program to stitch one or more lines of stitching following a second programmed stitch pattern, said second programmed stitch pattern having a repeat length set equal to or greater than a length of a side or end of a second said mattress or foundation having a size different from said first size, wherein said second programmed stitch pattern includes a second prime pattern comprising plural said stitch pattern elements arranged to provide aperiodic pattern element variation along said repeat length, which length is equal to or greater than the length of the side or end of the second mattress or foundation, said second prime pattern emulating said first prime pattern, but being scaled to said mattress or foundation of said second size;
• cutting said quilted material into segments of predetermined lengths corresponding to the perimeter lengths of said mattress or foundation of said first size and said second side and comprising, respectively, said first and second prime patterns, to thus form a first said quilted border loop sidewall panel of material of a first length with said pattern elements arranged at predetermined positions therealong, and a second said quilted border loop sidewall panel of material of a second length with said pattern elements arranged at predetermined positions therealong;
• wherein said first and second quilted border loop sidewall panels are configured to form part of a said mattress or foundation of said first and second sizes, respectively, with predetermined registry of the pattern elements with selected other portions of the respective mattress or foundation, to thus form a desired, reproducible aesthetic effect with said aperiodic pattern variation appearing along said side or end of the respective mattress or foundation.