A process and apparatus for manufacturing a mattress generally includes an automated foam layer placement apparatus for accurately securing one or more foam layers onto an innercore unit and bucket assembly.

A circulating-type mattress cleaning machine, including a rack; a horizontal barrel, an inner container frame and a circulating pipeline. A cylindrical cavity is formed inside the horizontal barrel. The inner container frame rotatably mounted inside the cylindrical cavity around an central axis of the cylindrical cavity, and is designed for bearing multiple mattresses side by side and driving the mattresses to rotate around the central axis. Two spray pipes are provided at a top of the cylindrical cavity and on one side of the top of the cylindrical cavity, respectively. Multiple spray nozzles are successively provided on the spray pipe, the spray nozzles directly face the mattresses carried by the inner container frame. The circulating pipeline in fluid communication with a bottom of the cylindrical cavity, and the circulating pipeline being in communication with two spray pipes.

A method and apparatus for deconstructing a mattress of the type having steel coil springs held within fabric pockets. The apparatus includes a frame and an opener mechanism mounted to the frame and operable for opening a plurality of fabric pockets at a first end thereof to create an opening in the first end of the fabric pockets and expose the steel coil springs contained therewithin. A gripper mechanism is provided for gripping the plurality of fabric pockets at a second end thereof, opposite the first end. An extractor mechanism is mounted to the frame for extracting the steel coil springs from the fabric pockets through the openings formed in the first end of the fabric pockets.

A circulating-type mattress cleaning machine, including a rack; a horizontal barrel, an inner container frame and a circulating pipeline. A cylindrical cavity is formed inside the horizontal barrel. The inner container frame rotatably mounted inside the cylindrical cavity around an central axis of the cylindrical cavity, and is designed for bearing multiple mattresses side by side and driving the mattresses to rotate around the central axis. Two spray pipes are provided at a top of the cylindrical cavity and on one side of the top of the cylindrical cavity, respectively. Multiple spray nozzles are successively provided on the spray pipe, the spray nozzles directly face the mattresses carried by the inner container frame. The circulating pipeline in fluid communication with a bottom of the cylindrical cavity, and the circulating pipeline being in communication with two spray pipes.

In order to manufacture an innerspring unit comprising pocketed springs and having an increased stability at its edge regions, in a first step, an innerspring main body comprising a plurality of first strings of pocketed springs is provided. In a subsequent second step, at least one second string of pocketed springs is attached to a lateral surface of the innerspring main body, so that the at least one second string of pocketed springs extends in a longitudinal direction of the innerspring main body. The springs of the at least one second string of pocketed springs have a spring characteristic or a spring geometry different from the springs of the plurality of first strings of the innerspring main body. The at least one second string of pocketed springs forms together with the innerspring main body the innerspring unit.