A mattress edge sewing machine including a frame with a drive shaft rotatably mounted therein and having a material supporting surface, a sewing station defined by a needle bar mounted in the frame for generally vertical reciprocatory movements along a fixed centerline and a feed mechanism for pulling materials along a generally horizontal direction thereby facilitating advancement of multiple mattress material plies through the sewing station of the machine. The feed mechanism includes upper and lower positively driven feed rollers which are continually biased into operable engagement with each other. The feed rollers are arranged in the line of feed of the material and within a range of about 0.4 inch to about 1.0 inch rearwardly of the needle bar centerline whereby facilitating advancement of material through a sewing station on the machine and especially around four corners of a mattress being sewn. The needle bar is moved in timed relation relative to the movements of the looper, and with the needle bar traversing a distance in a single vertical direction at a ratio greater than 2:1 relative to the distance in a single lateral direction traversed by the looper.
A mattress cover 1 comprising an upper layer 2a having a hem 5, a padding 3 provided under the upper layer 2a, and a liquid-impermeable backing layer 4, wherein the liquid-impermeable layer 4 is fastened to the upper layer 2a, at the hem 5 of the upper layer 2a and at least at two or more additional points 10.
A mattress and a method of manufacturing a mattress are disclosed. The mattress includes a mattress core, a side rail joined to the mattress core by a one or more adhesive patches, optionally a deck applied over an area of the mattress core and joined to the mattress core by adhesive patches, and an upholstery layer defining a sleep surface applied over the deck or the mattress core and joined to the deck by adhesive patches. The adhesive patches have a bonding strength sufficient to maintain a relative position between the various mattress components at least during assembly of the mattress. The upholstery layer is permanently secured to the side rail by, for example, sewing or stapling.
A mattress has cells with low air permeability envelopes. Check valves permit air flow into cell groups. An inflation structure expands within the cells when not loaded to cause the envelope to fill with air through the check valves. Another mattress has a cell with a primary bladder, a hollow inflation structure in the primary bladder, a secondary bladder in the hollow inflation structure. The inflation structure expands when not under load to cause the primary bladder to fill with air through the check valve. An air cell has a bladder, a check valve permitting air flow to the bladder, and an inflation structure that expands in the bladder when not under load to cause the bladder to fill with air through the check valve. The inflation structure is a cylindrical foam structure with a portion removed along a surface and a D-shaped hollow space within an upper portion thereof.