Patent ID: 7631381

Claim:
A method of making a mattress, said method comprising steps of constructing a resilient tub having a peripheral resilient wall and a resilient bottom panel by permanently connecting two resilient end rails and two resilient side rails to the bottom panel along the periphery thereof, inserting a mattress core unit into the envelope, permanently connecting a top resilient panel to the top periphery of the wall to completely enclose the mattress core unit in a resilient envelope, and applying a fabric covering over the resilient envelope, wherein said applying step comprises steps of forming a band of border material, attaching a bottom fabric cover to the lower edge of the border band by sewing the periphery of the bottom cover to one edge of the border band, thereby forming a fabric tray, and then pulling the fabric tray over the resilient envelope so that the border band surrounds the resilient wall, securing the fabric tray to the resilient envelope, and then attaching a top fabric cover to the border band by sewing the periphery of the top cover to the top edge of the border band.