Abstract: A system for automatically attaching a flanging material to the edges of a panel such as for a mattress, including a work table on which the panel is supported and a sewing assembly having a sewing machine located along a path of travel of the panel across the work table. The flanging material is fed from a supply of flanging material located adjacent the sewing assembly, and is attached to the side edges and about the corners of the panel by the sewing machine of the sewing assembly. A clamp mechanism engages and holds the panel as the sewing machine of the sewing assembly attaches the flanging material about the corners of the panel.

Abstract: A system for quilting fabric materials includes a quilter unit having a reciprocating needle bar with a series of needles spaced therealong and carrying a series of threads for forming quilted patterns in fabric materials passing below the needles. The quilted fabric materials then can be collected on a supply roll or fed to a panel cutter downstream from the quilter unit. The panel cutter can include a panel cutting blade for cutting the quilted material in different panel lengths or sizes, as well as a series of slitting blades that can be moved into engagement with the quilted material for forming strips of the quilted material in desired widths.

Abstract: A tape edge applicator workstation including a conveyor for moving a mattress or foundation along a sewing path through a tape edge applicator. The tape edge applicator applies a tape edge material about the peripheral side edges of the mattress, with the mattress generally being rotated as the tape edge material is applied about the corners thereof.

Abstract: A system for automatically stretching and stapling a foundation cover to a spring unit for a foundation, including a support table for supporting the foundation and cover, and a series of stretching/stapling assemblies or units positioned along the support table. The stretching/stapling assemblies include a series of tension applicators that engage and pull the cover taut against the sides of the spring unit of the foundation, while staplers are lowered into engagement with the cover and foundation frame, automatically stapling the cover to the sides of the foundation frame.

Abstract: A process and apparatus for forming a mattress. A border material is fed through a sewing station to form a hem. The same material is fed through the sewing station again, at a different elevation to form a second hem and an attachment gusset. The hemmed gusset and border material then is preferably subjected to a ruffling process to form a series of pleats about the corners of the mattress border. The perimeter of the border is then closed, and the finished border is placed over a set of mattress springs and fixed in place.

Abstract: An automatic panel cutting and edge seaming system includes a series of side edge cutting and seaming assemblies that receive a fabric material and trim and sew seams along the side edges of the fabric material to form a desired width panel. Puller rolls pull the material through the side edge cutting and seaming assemblies and feed the trimmed and seamed fabric material to a cross-cut sewing assembly. After a sufficient length of fabric material has been fed to form a desired size panel, the cross-cut sewing assembly is engaged to cut and seam the end of the panel.

Abstract: A packaging machine for packaging a product. The machine has a frame for supporting the product and a source of packaging material for supplying packaging material into a position to be engaged by and at least partially surround the product. At least one upper sealing assembly is adapted to move between an actuated position and a non-actuated position. The upper sealing assembly comprises at least one sealing element for forming a seal along adjacent edges of the packaging material. At least one lower sealing assembly is adapted for cooperating engagement with the upper sealing assembly in its actuated position. The at least one upper and lower sealing assemblies are positioned for clamping engagement of the packaging material therebetween for forming the seal when the upper sealing assembly is moved to its actuated position in engagement with the lower sealing assembly.

Abstract: A tape edge applicator workstation including a conveyor for moving a mattress or foundation along a sewing path through a tape edge applicator. The tape edge applicator applies a tape edge material about the peripheral side edges of the mattress, with the mattress generally being rotated as the tape edge material is applied about the corners thereof.

Abstract: An apparatus for attaching a gusset to a panel includes a gusset folder that receives and folds a gusset material to form the gusset. The panel is supported by a sewing table. A sewing machine is positioned relative to the sewing table so as to be able to sew the gusset to the panel. A gusset guide guides the gusset toward a selected edge of the panel so that the gusset is held in substantial alignment with the edge of the panel. An edge detector detects when a next edge of the panel is approaching the sewing machine. A turning mechanism is positioned along the sewing table and is moveable into engagement with the panel. The turning mechanism turns the panel relative to the sewing machine when the edge detector detects the next edge of the panel is approaching the sewing machine.

Abstract: A packaging machine for packaging a product. The machine has a frame for supporting the product and a source of packaging material for supplying packaging material into a position to be engaged by and at least partially surround the product. At least one upper sealing assembly is adapted to move between an actuated position and a non-actuated position. The upper sealing assembly comprises at least one sealing element for forming a seal along adjacent edges of the packaging material. At least one lower sealing assembly is adapted for cooperating engagement with the upper sealing assembly in its actuated position. The at least one upper and lower sealing assemblies are positioned for clamping engagement of the packaging material therebetween for forming the seal when the upper sealing assembly is moved to its actuated position in engagement with the lower sealing assembly.

Abstract: A tape edge applicator workstation including a conveyor for moving a mattress or foundation along a sewing path through a tape edge applicator. The tape edge applicator applies a tape edge material about the peripheral side edges of the mattress, with the mattress generally being rotated as the tape edge material is applied about the corners thereof.

Abstract: An improved spring construction for mattresses, box springs, furniture and other applications is provided. The application of such springs in mattresses, box springs, furniture and other applications is also provided. In one aspect of the invention, the spring construction is a spring including a series of spring segments, each having a flattened, irregular configuration where the spring varies in compression strength and deflection from a top portion thereof to a bottom portion thereof.

Abstract: A label inserter system for inserting and sewing a label or law tag into a border for a mattress or foundation during the formation of the border. The label inserter system generally includes a hopper, a label pre-feeder and a label transfer clamp subassembly that engages and moves the label from the hopper and inserts the label between, on top or on the bottom of the cut edges of the border prior to sewing the cut edges to finish the border, with the label being sewn therein.

Abstract: A system for forming and attaching pillowtop attachment gussets and borders to panels, with the gusset or border material being fed from a supply into a sewing station. The gusset or border material is passed through a folder assembly that directs the gusset or border material into a sewing zone where it is attached to the panel. A ruffler mechanism engages and forms a series of ruffles in the gusset or border material as it is sewn about the corners of the panel.

Abstract: A method of forming a mattress, with a reduction in the number of sewing operations required, in which a border and gusset or an extended portion of the border will be integrally formed and attached to a mattress panel, with a flanging material also being attached as needed, to form a mattress cover or sleeve. A tape edge also can be applied for providing a more decorative appearance. Thereafter, the mattress cover or sleeve can be applied over a mattress spring set.