Mattress manufacturing process and apparatus

A process for applying an adhesive to a top surface of an innercore unit and bucket assembly, comprising:

• transferring the innercore unit and bucket assembly onto a planar conveying surface of an adhesive application station;
• moving the planar conveying surface carrying the innercore unit and bucket assembly along a travel path;
• detecting a leading edge of the innercore unit and bucket assembly with a sensor;
• automatically spraying a controlled amount of an adhesive in a defined pattern onto the top surfaces of the innercore unit and bucket assembly beginning at the leading edge to a trailing edge, wherein automatically spraying the controlled amount of the adhesive comprises discharging the adhesive from a bridge spanning across the travel path, wherein the bridge comprises a plurality of spray nozzles movable across the bridge in fluid communication with a source of the adhesive, wherein the plurality of spray nozzles are located on the bridge;
• adjusting the controlled amount of adhesive based on density and hardness properties of a foam layer providing the top surfaces;
• detecting the trailing edge of the innercore unit and bucket assembly;
• and
• discontinuing the spraying of the adhesive.