US 11,718,935 B2
Quilted border loop sidewall panel for bed mattress or foundation and method of making same
David M. Ramsay, Louisville, KY (US); and Richard Askren, Prospect, KY (US)
Assigned to Louisville Bedding Company, Louisville, KY (US)
Filed by Louisville Bedding Company, Louisville, KY (US)
Filed on Jan. 12, 2022, as Appl. No. 17/573,891.
Prior Publication US 2023/0220596 A1, Jul. 13, 2023
Int. Cl. D05B 11/00 (2006.01); D05B 69/30 (2006.01)
CPC D05B 11/005 (2013.01) [D05B 69/30 (2013.01)] 21 Claims
OG exemplary drawing
 
1. A method of making a quilted border loop sidewall panel of material for a bed mattress or foundation, wherein plural layers of material are fed from one or more rolls through a programmable multi-needle quilting machine in registry with each other and are pressed and stitched together to form a quilted material, said plural layers of material being controllably moveable laterally with respect to a material feed direction and at least one needle bar-mounted needle of the machine in order to form, during stitching, stitch pattern elements which extend in both the material feed direction and laterally thereto, said method comprising:
executing on a controller of the multi-needle quilting machine a program to stitch one or more lines of stitching following a programmed stitch pattern, said stitch pattern having a repeat length set equal to or greater than a length of a side or end of said mattress or foundation, wherein said stitch pattern includes a prime pattern comprising plural said stitch pattern elements arranged to provide aperiodic pattern element variation along its length, which length is equal to or greater than the length of the side or end of the mattress or foundation;
carrying out stitching of said plural layers of material on said multi-needle quilting machine in accordance with said programming, in order to form a quilted material comprising said prime pattern; and
cutting said quilted material into segments of predetermined length corresponding to a perimeter length of said mattress or foundation and comprising said prime pattern to thus form a said quilted border loop sidewall panel of material with said pattern elements arranged at predetermined positions therealong;
wherein said quilted border loop sidewall panel is configured to form part of a said mattress or foundation with predetermined registry of the pattern elements with selected other portions of the mattress or foundation, to thus form a desired, reproducible aesthetic effect with said aperiodic pattern variation appearing along said side or end of the mattress or foundation.