Abstract: A method of manufacturing a mattress including providing a foam block, convoluting the foam to form a tongue extending longitudinally along the foam block, and removing at least a portion of the tongue, to thereby form a channel within the foam block.

Abstract: A mattress having an inverted top panel/border seam, with an optional appended decorative rope welting on the border is described. An inverted seam secures the top panel to the border portion of a mattress cover to eliminate bumps and creases found in conventional welted top seam. Manufacturing costs may be reduced by eliminating the need for an expensive table-mounted tape edge closure machine and/or skilled operators, since the inverted seam may be flay sewn with a conventional sewing machine or even hand-stitched. Alternatively, a conventional tape edge machine can be used with less-skilled labor and or reduced tape/welting material, as all of the stitches and welting are hidden inside the mattress by the inverted seam.