Pillow Cover with Side Gussets and Method of Construction

A pillow shell comprising:

• a first and a second rectangular body panel, each with first and second lateral edges of a predetermined length and transverse edges of a predetermined width;
• a first and a second rectangular side panel each with first and second lateral edges of the predetermined length and transverse edges of a lesser predetermined width;
• wherein the first lateral edges of the first and second side panels are sewn respectively to the first and second lateral edges of the first body panel to create first and second lateral seams and the second lateral edges of the first and second side panels are sewn respectively to the first and second lateral edges of the second body panel to create third and fourth lateral seams;
• the body panels and side panels connected by the first, second, third and fourth lateral seams defining a tube;
• and
• a first transverse end seam closing one end of the tube, said end seam connecting a transverse edge of each of the first and second body panels and folded transverse edge of each side panel upon itself;
• wherein the inlay of each of the four lateral seams and the first end seam is on the interior of the closed ended tube.

A method of manufacturing a pillow from first and second rectangular body panels each with first and second lateral edges of a predetermined length, transverse edges of a predetermined width, and a first surface to be outward facing and a second opposite surface to be inwardly facing in the assembled shell;

• first and a second rectangular side panels each with first and second lateral edges of the predetermined length, transverse edges of a lesser predetermined width, and a first surface to be outward facing and a second opposite surface to be inwardly facing in the assembled shell, and a fill material, comprising the steps of:
• placing the first lateral edge of the first rectangular side panel along the first lateral edge of the first rectangular body panel such that the outward facing surface of the first rectangular side panel is overlaying and facing the outward facing surface of the first body panel;
• sewing a first lateral seam along the first lateral edges of the first rectangular side panel and the first rectangular body panel to connect said panels;
• placing the first lateral edge of the second rectangular side panel along the second lateral edge of the first rectangular body panel such that the outward facing surface of the second rectangular side panel is overlaying and facing the outward facing surface of the first body panel;
• sewing a second lateral seam along the first lateral edge of the second rectangular side panel and second lateral edge of the first rectangular body panel to connect said panels;
• folding open the first rectangular side panel along the first lateral seam to expose the outward facing surface of the first rectangular side panel;
• placing the first lateral edge of the second rectangular body panel along the second lateral edge of the first rectangular side panel such that the outward facing surface of the second rectangular body panel is overlaying and facing the outward facing surface of the first rectangular side panel;
• sewing a third lateral seam along the first lateral edge of the second rectangular body panel and the second lateral edge of the first rectangular side panel to connect said panels;
• placing the second lateral edge of the second rectangular body panel along the second lateral edge of the second rectangular side panel such that the outward facing surface of the second rectangular body panel is overlaying and facing the outward facing surface of the second rectangular side panel;
• sewing a fourth lateral seam along the second lateral edges of the second rectangular body panel and the first rectangular side panel to connect said panels, thereby forming a tubular structure of alternating rectangular body panels and rectangular side panels with the outward facing surfaces of the panels on the interior of the tubular structure;
• placing the first transverse edge of the first rectangular body panel along the first transverse edge of the second rectangular body panel and positioning the outward facing surface of the second rectangular body panel to be overlaying and facing the outward facing surface of the first rectangular body panel;
• laterally folding the outward facing surface of the first rectangular side panel upon itself so that the first transverse edge of said panel is folded upon itself;
• laterally folding the outward facing surface of the second rectangular side panel upon itself so that the first transverse edge of said panel is folded upon itself;
• sewing a first transverse seam across the folded first transverse edge of the first rectangular side panel, the first transverse edges of the first and second rectangular body panels, and the folded first transverse edge of the second rectangular side panel to close an end of the tubular structure;
• inverting the tubular structure so that the outward facing surfaces of the rectangular panels are on the exterior of the tubular structure;
• inserting a fill material into the tubular structure;
• placing the second transverse edge of the first rectangular body panel along the second transverse edge of the second rectangular body panel;
• folding the second transverse edge of the first rectangular side panel upon itself;
• folding the second transverse edge of the second rectangular side panel upon itself;
• sewing a second transverse seam across the folded second transverse edge of the first rectangular side panel, the second transverse edges of the first and second rectangular body panels, and the folded second transverse edge of the second rectangular side panel to enclose the fill material within the tubular structure formed from the rectangular side and body panels.