Patent ID: 7543364

Claim:
Apparatus for forming a one-piece border for a mattress comprising: a feeding section for providing a length of border material along a substantially vertically oriented path of travel; a rewinding section downstream from said feeding station for receiving the border material; a sewing station, including a sewing head, positioned along the path of travel between said feeding and rewinding sections for sewing at least one faux seam in the border material; a folder blade for folding the border material as the border material moves through said sewing station for sewing said at least one faux seam defining the one-piece border with a gusset portion therein, by said sewing head; a drive system for moving the border material in a substantially vertical orientation from said feeding section, through said sewing station, and to said rewinding section; and a first active edge guide mechanism, between said feeding section and said sewing station, for maintaining the border material at a substantially fixed vertical elevation relative to said sewing station.