Abstract: In systems and methods for adjusting the firmness of a mattress assembly and/or modulating the pressure in a mattress assembly, a mattress assembly includes: a two-dimensional array of bladders; at least one pump that is in fluid communication with the bladders to provide air and/or fluid to the bladders; multiple valves that are interposed between the pump and the bladders to control the flow of air and/or fluid to or from the bladders; a pressure sensor operably connected to one or more of the bladders; and a controller in communication with the pump, the valves, and the pressure sensors. The controller is configured to selectively actuate the pump and one or more of the valves, while receiving feedback from the pressure sensors, in order to adjust the firmness of the mattress assembly and/or modulate the pressure in the mattress assembly.

Abstract: A hybrid pillow includes a first coil panel and a second coil panel which are joined along peripheral edges to form an inner shell defining a gap therebetween. The first coil panel is formed of a plurality of coil springs, an upper fabric layer, and a lower fabric layer, with the upper fabric layer and the lower fabric layer joined between the plurality of coil springs and along peripheral edges of the first coil panel. The second coil panel is formed of a second plurality of coil springs, a second upper fabric layer, and a second lower fabric layer, with the second upper fabric layer and the second lower fabric layer joined between the plurality of coil springs and along peripheral edges of the second coil panel. A support material disposed in the gap of the inner shell, and one or more additional layers disposed about the inner shell.

Abstract: Present embodiments provide various open coil spring assemblies which perform like an encased spring assembly. The embodiments have elastic lacings or connections which connect springs to springs or springs to lacings. Various spring embodiments are provided as well as various arrangements for the elastic lacings. All of these features improve compliance and stability while reducing motion transfer.

Abstract: A support cushion for providing air flow to a user resting on the support cushion is provided. The support cushion includes pocketed coil layer and a base layer positioned adjacent to and below the pocketed coil layer. The pocketed coil layer including a plurality of fabric types for directing air flow. A fan is operably connected to the inlet hole of the base layer to provide air flow into and through the pocketed coil layer to a body support layer. Methods of controlling air flow through a support cushion are also provided.

Abstract: A spring core is provided that includes a plurality of coil springs having an upper portion and a lower portion that collectively define an interior cavity. The spring core further includes a continuous upper fabric layer that covers each coil spring and defines a recess in the interior cavity of each coil spring. A cushioning layer is positioned atop the continuous upper fabric layer and extends into the recess in the interior cavity of each coil spring. A mattress assembly is further provided that includes the spring core, an upper body supporting layer, and a lower foundation layer. Methods of producing a spring core are further provided.

Abstract: In systems and methods for adjusting the firmness of a mattress assembly and/or modulating the pressure in a mattress assembly, a mattress assembly includes: a two-dimensional array of bladders; at least one pump that is in fluid communication with the bladders to provide air and/or fluid to the bladders; multiple valves that are interposed between the pump and the bladders to control the flow of air and/or fluid to or from the bladders; a pressure sensor operably connected to one or more of the bladders; and a controller in communication with the pump, the valves, and the pressure sensors. The controller is configured to selectively actuate the pump and one or more of the valves, while receiving feedback from the pressure sensors, in order to adjust the firmness of the mattress assembly and/or modulate the pressure in the mattress assembly.

Abstract: A spring core is provided that includes a plurality of coil springs having an upper portion and a lower portion that collectively define an interior cavity. The spring core further includes a continuous upper fabric layer that covers each coil spring and defines a recess in the interior cavity of each coil spring. A cushioning layer is positioned atop the continuous upper fabric layer and extends into the recess in the interior cavity of each coil spring. A mattress assembly is further provided that includes the spring core, an upper body supporting layer, and a lower foundation layer. Methods of producing a spring core are further provided.

Abstract: In systems and methods for adjusting the firmness of a mattress assembly and/or modulating the pressure in a mattress assembly, a mattress assembly includes: a two-dimensional array of bladders; at least one pump that is in fluid communication with the bladders to provide air and/or fluid to the bladders: multiple valves that are interposed between the pump and the bladders to control the flow of air and/or fluid to or from the bladders; a pressure sensor operably connected to one or more of the bladders; and a controller in communication with the pump, the valves, and the pressure sensors. The controller is configured to selectively actuate the pump and one or more of the valves, while receiving feedback from the pressure sensors, in order to adjust the firmness of the mattress assembly and/or modulate the pressure in the mattress assembly.

Abstract: A coil-in-coil spring is provided that exhibits a variable and non-linear loading response upon compression. The spring comprises a continuous wire including a first spring portion having a first spring constant, a second spring portion having a second spring constant less than the first spring constant, and a third spring portion having a third spring constant less than the first spring constant and less than the second spring constant. In the coil-in-coil spring, the first spring portion forms an outer coil of the coil-in-coil spring and the second spring portion, the third spring portion, or both the second spring portion and the third spring portion are positioned within the first spring portion and form an inner coil of the coil-in-coil spring. A multi-coil spring is also provided that includes an outer coil, an intermediate coil positioned within the outer coil, and an inner coil positioned with the intermediate coil.

Abstract: A coil-in-coil spring is provided that exhibits a variable loading response as the spring is compressed. The coil-in-coil spring comprises a continuous wire forming’ an inner coil having a substantially conical shape and an outer coil extending around the inner coil and having a substantially cylindrical shape. The inner coil includes a plurality of helical convolutions with diameters that progressively decrease as the plurality of helical convolutions extend from a lower end of the coil-in-coil spring to an upper end convolution of the inner coil. The inner coil also has an uncompressed height that is about 75% of the uncompressed height of the outer coil, A mattress is further provided and includes the coil-in-coil springs arranged in a matrix.

Abstract: A mattress assembly is provided that includes a mattress core having a bottom surface and a top surface opposite the bottom surface, and a mattress topper positioned adjacent to the top surface of the mattress core. The mattress topper includes a plurality of coil springs, an upper fabric layer extending above the plurality of coil springs, and a lower fabric layer extending below the plurality of coil springs. The lower fabric layer is connected to the upper fabric layer around each coil spring such that the upper fabric layer and the lower fabric layer collectively form a fabric pocket encasing each coil spring. The mattress topper further includes a padded layer positioned atop the upper fabric layer, with the padded layer connected to the upper fabric layer by ultrasonic welds and/or tufts. Methods of producing a mattress topper for connection to a mattress core are further provided.

Abstract: A pocketed spring, such as that used in a mattress, comprises: a compression spring having an upper end convolution and a lower end convolution opposite the upper end convolution, and a plurality of helical intermediate convolutions between the upper end convolution and the lower end convolution; a flexible enclosure including a top wall positioned adjacent to the upper end convolution of the compression spring, a bottom wall positioned adjacent to the lower end convolution of the compression spring, and a side wall that extends from the top wall to the bottom wall; and a tension member connected to the flexible enclosure. The tension member acts in opposition to the compression spring until the pocketed spring is compressed to a point at which the tension member no longer applies any force. Thus, the pocketed spring exhibits a non-linear response when compressed.

Abstract: A spring is provided that exhibits a variable and non-linear loading response upon compression. The spring comprises a continuous wire having a lower end convolution, an upper end convolution, and a plurality of helical intermediate convolutions. The upper end convolution, the lower end convolution, and the helical intermediate convolutions each have a respective diameter, with the continuous wire further defining a pitch between the various convolutions. In the spring, one or more of the diameters of the convolutions or one or more of the pitches varies along the length of the continuous wire such that the spring exhibits a non-linear loading response upon compression. A mattress is further provided and includes a plurality of the springs arranged in a matrix.

Abstract: A pocketed spring, such as that used in a mattress, comprises: a compression spring having an upper end convolution and a lower end convolution opposite the upper end convolution, and a plurality of helical intermediate convolutions between the upper end convolution and the lower end convolution; a flexible enclosure including a top wall positioned adjacent to the upper end convolution of the compression spring, a bottom wall positioned adjacent to the lower end convolution of the compression spring, and a side wall that extends from the top wall to the bottom wall; and a tension member connected to the flexible enclosure. The tension member acts in opposition to the compression spring until the pocketed spring is compressed to a point at winch the tension member no longer applies any force. Thus, the pocketed spring exhibits a non-linear response when compressed.

Abstract: A support cushion for providing individualized heating and cooling to a user resting on the support cushion is provided. The support cushion includes a body supporting layer and a base layer positioned adjacent to and below the body supporting layer. The base layer defines a cavity with a support insert positioned within the cavity. The support insert includes a bag defining one or more outlet holes positioned adjacent to the body supporting layer and further defining an inlet hole. A fan is operably connected to the inlet hole of the bag to provide air flow into the inlet hole of the bag and out of the one or more outlet holes of the bag. Methods of controlling the surface temperature of a support cushion are also provided.