Method and system of manufacturing a mattress and components thereof

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 at a first sewing station;
• sewing a first web of flange material to the web of gusset material along a second seam at the first sewing station, 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 wherein said third seam is sewn at a second sewing station remote from the first sewing station.

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 wherein the first seam is sewn at a first sewing machine and the second seam is sewn at a second sewing machine.

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;
• sewing a bottom panel to the border assembly loop;
• and
• marking the web of border material at predetermined locations to aid in sewing the bottom panel to the border assembly loop.

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 by providing an encoder 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;
• sewing a bottom panel to the border assembly loop.

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 predetermined length by providing an encoder to create a border assembly piece;
• sewing the ends of the border assembly piece together to create a border assembly loop;
• sewing a bottom panel to the border assembly loop.

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 at a first sewing station;
• sewing a first web of flange material to the web of gusset material along a second seam at the first sewing station, 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 at a second sewing station remote from the first sewing station;
• ruffling the webs of flange and gusset material at predetermined positions to complete a border assembly web by providing an encoder;
• 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 wherein sewing said third seam occurs at a second sewing station remote from the first sewing station.

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.

A method of manufacturing a bedding or seating product, said method comprising:

• sewing a web of border material to a web of gusset material proximate aligned edges of the webs;
• sewing a first web of flange material to the web of gusset material along an edge of the gusset material oppose the edge of the gusset material joined to the border material to create a three piece web, the web of flange material overlaying the web of gusset material;
• sewing the webs of flange and gusset material along a longitudinally extending seam spaced inwardly from the sewn edges of the webs of flange and gusset material, said sewing including 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;
• sewing a bottom panel to the border assembly loop to complete a casing;
• inserting a spring core into the casing;
• laying padding materials over the spring core;
• sewing a top panel to an outer edge of the gusset material of the casing;
• and inserting a second web of flange material between the border assembly loop and the bottom panel prior to sewing the bottom panel to the border assembly loop.