Method and System of Manufacturing A Mattress and Components Thereof
AssigneeL&P Property Management Company
InventorsDustin W. Smith, Kyle W. McClintock, Nathaniel T. Harris, Steven Marcangelo
Life of this patent
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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.
Claims20
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.
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.
Dependencies are inferred from the claim text.