Abstract: Vertically lapped nonwoven material is used without cross lapped nonwoven to provide enhanced breathability and comfort in mattresses by replacing foam material in one or more of, including all of top panel quilts, layers underneath the top panel quilts, and in side blocks which surround spring supports. The vertically lapped nonwoven may provide advantages in terms of cost, manufacturing ease, robustness in mattress design, while at the same time providing the user with a much more comfortable sleeping experience.

Abstract: Vertically lapped nonwoven material is used to provide enhanced breathability and comfort in mattresses by replacing foam material in one or more of, including all of top panel quilts, layers underneath the top panel quilts, and in side blocks which surround spring supports. The vertically lapped nonwoven may provide advantages in terms of cost, manufacturing ease, robustness in mattress design, while at the same time providing the user with a much more comfortable sleeping experience.

Abstract: The present disclosure relates to a regimen mattress. The regimen mattress includes a memory foam, a high density (HD) foam below the memory foam, and a cover covering the memory foam and the HD foam together to form the entire mattress. The HD foam contains functional additives. The regimen mattress effectively improves the user's health condition through adding functional additives into the foam layer that is far away from the user.

Abstract: An apparatus and method are provided for a sofa seat cushion comprising a cushion core including a multiplicity of pocketed springs enclosed within an upholstery foam envelope. The pocketed springs are positioned side by side in a spring layer arrangement and are independently operable. A memory foam layer positioned above the upholstery foam envelope comprises a material capable of molding to a person's body sitting on the sofa seat cushion and then quickly returning to an original shape once the person leaves the sofa seat cushion. The memory foam layer comprises a gel-infused visco-elastic memory foam with a polyethylene terephthalate layer positioned there above. Directly below the upholstery foam envelope is an upholstery-grade polyurethane foam layer with a polyethylene terephthalate layer positioned directly thereunder. An exterior upholstery surrounding the cushion core provides a plush seating surface.

Abstract: A mattress comprising a foam base, a foam core, and a foam comfort layer. The foam core may be reinforced with firmer transverse members selectively placed along the length of the core. The core may also include air passages. The comfort layer may comprise interlocking upper and lower layers configured to form ventilation channels that operate in a bellows-like fashion moving moist, warm out and drawing fresh air in as the sleeping body moves and shifts through the sleep cycle. The ventilation channels in the core and the comfort layer provide for effective dissipation of heat and moisture even from the innermost regions of the mattress. A cooling gel top layer may be included, and the entire assembly may be covered with a fabric top panel and surround. The surround may be vented to facilitate air movement in and out of the mattress.

Abstract: A mattress assembly may include a foam frame, an inner assembly within the foam frame, the inner assembly including a foam core and a pocketed coil assembly. The pocketed coil assembly can include a plurality of individual pocketed coil springs having a height. Each coil spring may be joined together to a neighboring coil spring such that at least a majority of the height of each coil spring is configured to vertically deflect without deflecting the joined neighboring coil spring.

Abstract: A spring wire support for foundations and innerspring mattresses, and a variable spring surface deck for a foundation and variable spring surface for a mattress. The spring wire support comprises an elongated spring element enveloped in a pliant carrier, with the carrier including an attachment margin. The variable spring surface deck for a foundation comprises a plurality of the spring wire supports secured as desired to an upper surface of a foundation. The variable spring surface for a mattress comprises a plurality of the spring wire supports located between top and adjacent convolutions of rows or columns of springs of the mattress.

Abstract: A mattress core including an array of strings of pocket springs extending in parallel across the mattress core; and a fastener coupling the array of strings of pocket springs together, wherein said array of strings of pocket springs includes single strings of pocket springs and double strings of pocket springs, each double string of said double strings of pocket springs including a superior string of pocket springs and an inferior string of pocket springs.

Abstract: A bedding or seating product comprising a spring core including at least one border wire and a plurality of coil springs. Each of the border wires is generally rectangular in cross-section to reduce wire costs without compromising beam strength of the border wire. Each of the coil springs may be made of a single piece of wire having a central spiral portion defining a central spring axis and terminating at opposed ends with upper and lower end turns. The coil springs may be arranged in side-by-side rows and columns and be connected with each other at the upper and lower end turns by helical lacing wires.

Abstract: In one embodiment, a mattress comprises a core and a cushion layer positioned above the core. A fibrous air spacer layer is positioned above the cushion layer, and a layer of visco-elastic foam is positioned above the fibrous layer. This permits the fibrous layer to be sandwiched between the cushion layer and the layer of visco-elastic material.

Abstract: A quilted zoned topper formed with a quilted panel and a memory foam is disclosed. The quilted panel has a ticking material, a backing material, and a support material having a degree of compression provided between the ticking and backing materials. The ticking material, the support material and the backing material all are quilted together by a stitching pattern providing an increased amount of stitching in a center section of the quilted panel than adjacent head and foot sections of the quilted panel such that the support material pre-compresses in the center section thereby defining a pocket. The memory foam is provided in the pocket. A mattress provided with the quilted zoned topper is also disclosed.

Abstract: Disclosed herein is a bed mattress and a method of manufacturing the same, in which a permeable reinforcing member is provided at an upper portion and a lower portion of a spring assembly which is one of frame constituents of the bed mattress, and a foaming material is disposed on the permeable reinforcing member so as to be foamed, so that the spring assembly and the foaming material are integrally formed while the foaming material is expanded through fine holes and/or foam expansion holes of the permeable reinforcing member.

Abstract: Disclosed herein is a bed mattress and a method of manufacturing the same, in which a permeable reinforcing member is provided at an upper portion and a lower portion of a spring assembly which is one of frame constituents of the bed mattress, and a foaming material is disposed on the permeable reinforcing member so as to be foamed, so that the spring assembly and the foaming material are integrally formed while the foaming material is expanded through fine holes and/or foam expansion holes of the permeable reinforcing member.

Abstract: A mattress includes reduced-firmness materials along a central region thereof in order to mitigate the occurrence of a central ridge following repeated use of the mattress as a sleeping surface. An associated box spring may also, or instead, present a central region with reduced firmness. An adjustable member may be employed to controllably compensate for the development of a central ridge.

Abstract: Disclosed herein is a bed mattress and a method of manufacturing the same, in which a permeable reinforcing member is provided at an upper portion and a lower portion of a spring assembly which is one of frame constituents of the bed mattress, and a foaming material is disposed on the permeable reinforcing member so as to be foamed, so that the spring assembly and the foaming material are integrally formed while the foaming material is expanded through fine holes and/or foam expansion holes of the permeable reinforcing member.

Abstract: In one embodiment, a mattress is constructed of a core having a first side and a second side. A padding layer is positioned at the first side of the core and has a contoured surface and a planar surface. A layer of individual fiberballs is disposed on the planar surface of the padding layer.

Abstract: A mattress core unit, such as an innerspring, is placed inside a foam envelope, which in turn is covered with fabric. The side and end rails of the envelope overlap the bottom panel, to provide good support for all edges of the mattress. The top panel of the envelope overlaps the side and end rails. To make a reversible mattress, an overlapping bottom foam panel is used. The method simplifies matress construction, reduces the number of required stock keeping units, and provides a comfortable, yet firm, feel at the edges of the mattress.

Abstract: A mattress component includes first and second layers to be assembled in a mattress over which a user will lie. The first layer of a first material has different properties than the second layer of a second material. The second layer has a surface underlying the surface of the first layer. Mating patterns are formed in the surfaces of the first and second layers. The mating patterns in the first and second layers are designed to substantially match the surfaces of the first and second layers with each other. The mating patterns in the first and second layers result in a greater effective thickness in one of the layers in areas corresponding to a position where hips and shoulders of the user will rest on the mattress, and a lesser effective thickness in other areas.

Abstract: At least one major surface of the core is covered with an inner layer of insulation, and at least one outer layer of material. The outer layer is secured to the inner layer by inserting flexible filament type fasteners through the hollow needle of an installation tool. If the core is made of foam, filamentary fasteners may also be used to secure the inner layer. The insulation layers are ultimately covered and secured in place by a fabric panel which conceals and secures the other components. Filamentary fasteners may also be used to secure a pillow top edge or a top panel to the mattress.

Abstract: In an adjustable springing mattress, including a plurality of parallelepipedal bodies made of a synthetic elastic material and being mutually coupled, each synthetic elastic material body houses an inner coil spring, each spring housing body being separated from adjoining bodies through a throughgoing hole, and on each side of the mattress, the corresponding spring housing bodies are partially separated by V-shape separating slots which longitudinally and transversely extends with respect to the mattress forming body.

Abstract: A mattress foundation with a perimeter structure has a frame, springs mounted upon the frame, and a grid supported by the springs, and perimeter structure at a perimeter of the frame which extends from the frame to the grid, forming an exterior wall which extends from the frame to a border wire of the grid. When the perimeter structure is made of structural and reflexive material such as closed-cell foam, it co-acts with the grid and springs and provides additional support to the perimeter region of the grid and foundation. The exterior wall of the perimeter structure forms a solid surface over which padding or upholstery is placed.

Abstract: Various embodiments of this invention disclose a mattress with two cover layers that enclose a spring grid array core wherein the springs are mounted back to back on a single grid support. The spring array is surrounded by a frame layer and is divisible into separate recumbence areas by supportive flanges.

Abstract: A method of making a mattress component includes providing a first layer of a first material. Mating patterns are shaped in a surface of the first layer in areas corresponding to a position where hips and shoulders of the user will rest on a mattress. The mating patterns in the surface of the first layer result in a greater effective thickness of the first layer in areas corresponding to the position where the hips and the shoulders will rest, and a lesser effective thickness of the first layer in other areas. A second layer has a second material with different properties than the first material. Mating patterns are shaped in a surface of the second layer in areas corresponding to the mating patterns of the first layer and shaped to substantially match with the mating patterns of the first layer.

Abstract: A molded foam-encased integrated flexible support device includes an innerspring positioned upon a three-dimensional thermoplastic foam deck as a flexible foundation, and a molded foam encasement which structurally integrates the foam deck with the innerspring by attachment to perimeter coils of the innerspring. A sculpted foam topper is adhesively bonded to a support surface of the foam-encased innerspring, forming a unitized mattress or support structure with fully integrated innerspring and internal and external foam components. The sculpted foam topper is designed with varying contours and densities to provide the desired support and feel characteristics for different comfort profiles. The foam encased innerspring with internal three-dimensional foam structures is upholstered for use as a mattress, seating, or other flexible support structure.

Abstract: A mattress spring structure (10) is provided with a strengthened central area (C) thereon to provide greater support for a user's body lumbar region when received thereon. The support is provided with a strengthening structure (30) having a continuous frame member (54) and a strengthening pattern (53). The continuous frame (54) encircles coil springs (12) over a major expanse of the mattress's central area (C); this frame is connected to mattress coils along the frames longitudinal (34, 36) and traverse (38, 40) segments. The strengthening pattern (53) has two metal bars (51, 52) arranged inside and connected to the continuous frame member (54). The strengthening pattern (53) may be connected to the spring coils (12) and contain additional metal straps (56, 59).

Abstract: A method of applying at least one web of insulator material to a plurality of spring assemblies is provided. Each web of insulator material is unwound from a roll, passed along a roller and applied to multiple spring assemblies which are passed between rollers. Each web of insulator material is folded around outermost coil springs along longitudinal edges of the spring assemblies. Side portions of each web of insulator material are glued, welded or otherwise permanently secured to a middle portion of the web of insulator material.

Abstract: Three-dimensional unitized thermoplastic foam structures are made by thermoplastic welding of different foam components. The unitized foam structures may include a planar base to which other foam components are welded to project from the base and provide a flexible three-dimensional structure. The thermal bonding or welding of the thermoplastic foam components creates a unitized structure which is both flexible and load bearing. For mattress and seating applications, the welded foam structures may be combined with an innerspring, and certain of the foam components of the structure may mechanically engage parts of the innerspring. The preferred foam deck has first and second panels interconnected by one or more webs. One or more foam decks may be employed. Other foam components may be attached to the foam decks or other components. The utilized foam structures can be employed as single or double-sided mattresses, seating structures or other flexible support structures.

Abstract: A body impression resistant mattress assembly comprised of an inner mattress unit, at least one raised sleep zone, a first cushion top, and an outer cover encasing the raised sleep zone and the first cushion top. The insert is sized and located within the mattress so that it inhibits the formation of body impressions.

Abstract: A mattress spring structure (10) is provided with a strengthened central area (C) thereon to provide greater support for a user's body lumbar region when received thereon. The support is provided with a strengthening structure (30) having a continuous frame member (54) and a strengthening pattern (53). The continuous frame (54) encircles coil springs (12) over a major expanse of the mattress's central area (C); this frame is connected to mattress coils along the frames longitudinal (34, 36) and traverse (38, 40) segments. The strengthening pattern (53) has two metal bars (51, 52) arranged inside and connected to the continuous frame member (54). The strengthening pattern (53) may be connected to the spring coils (12) and contain additional metal straps (56, 59).

Abstract: There is provided an innerspring assembly used in a mattress for absorbing external loads. An outermost coil spring 115 of a spring array 110 is secured in a space between upper and lower border wires 120 and 120? by pins 140, and helical coils 130 are disposed in row directions R on upper and lower portions of the spring array 110 to knit an adjacent coil spring 115, such that each coil spring has a free terminal convolution 115a protruded from an upper portion of the upper border wire 120 and/or a lower portion of the lower border wire 120?. The spring assembly includes an enclosure 10 partially or fully provided on an upper end portion and/or an lower end portion of the coil spring for covering the terminal convolution 115a in the row direction R or column direction L, thereby interrupting interference between the terminal convolution 115a and the upper and/or lower border wire 120 and 120? and absorbing a lateral load applied to the terminal convolution.

Abstract: An anti-microbial/-allergenic sleep set and process of forming thereof is provided and comprises a mattress and box spring, each having an allergen-impermeable barrier layer incorporated within. The mattress comprises a support apparatus, a top and bottom panel, first and second flanges, a border, a foam layer, and a barrier layer. The border is positioned around the support apparatus, and is attached to the top and bottom panels. The foam layer, which can comprise a latex emulsion, is positioned between the support apparatus and the top and bottom panels. The barrier layer comprises a material configured to be impermeable by allergens, and is attached at its outer periphery to the interior facing sides of the top panel, the bottom panel, and the border.

Abstract: In one embodiment, a mattress is constructed of a core having a first side and a second side. A first padding layer is positioned at the first side of the core and comprises a foam material having contoured surface facing away from the core. A second padding layer of a foam material is positioned adjacent the contoured surface of the first padding layer.

Abstract: A bedding or seating product comprises a pocketed spring assembly having a plurality of parallel strings of springs joined to each other. Each of said strings of springs comprises a row of interconnected pockets, each of the pockets containing at least one spring encased in a fabric pocket and with more than one line of attachment between at least selected adjacent pockets. At least one spacer strip or at least one scrim sheet extends between the interconnected pockets of at least one string of springs and is secured thereto to provide stability in the pocketed spring assembly.

Abstract: A bedding or seating product comprising a pocketed spring assembly made up of a plurality of parallel strings of springs joined to each other. Each of the strings of springs comprises a plurality of interconnected pocketed coil springs. The product has multiple sections of differing firmness attributable in part to differing heights of the pockets of the strings of springs. Filler is placed above the lower sections of the pocketed spring assembly.

Abstract: A novel support for use with furniture having a spring-edge is provided that includes a coil assembly. The coil assembly is typically square or rectangular with top and bottom surfaces and a front edge that faces the front of the furniture piece. A bridge is secured to the top surface of the coil assembly to provide support for the spring-edge. The bridge extends outwardly away from the front edge of the coil assembly and is supported in the same plane as the top surface of the coil assembly by a series of wires. The wire supports terminate at and hold a stiffening member in place that forms the upper portion of the spring-edge. The stiffening member is used to attach a series of front springs to the bridge. These springs are held in place on their lower end by the frame of the piece of furniture.

Abstract: A mattress has a quilted internal pillow wherein one or more internal layers of material are quilt-stitched prior to encapsulation in mattress upholstery. The quilted internal pillow is positioned relative to a support surface of an innerspring or spring core of a mattress to provide support characteristics determined by the quilt stitch pattern. In a related method of manufacture of a mattress with an internal quilt stitched pillow, the layer or layers of the pillow are processed through a quilter stitching machine and then assembled in combination with a mattress spring core and upholstery. The quilted internal pillow may be located adjacent to the spring core, spaced from the spring core by other internal layers of material, or located adjacent to or within a mattress pillowtop, and in each embodiment on one or both sides of the mattress.

Abstract: A selectively contoured single unibody foam piece for use as a layer in a cushioned load bearing structure has a first zone with a first surface topography having distinct support properties from a second zone with a second surface topography. The zones of differing topography are formed in the surface of a single, unibody piece of foam by applicable foam cutting techniques. Patterned removal of foam material from a single piece creates zones with different density, ILD or other load bearing properties with different support and feel characteristics. A single unibody component in a responsive flexible support structure has distinct zones with distinct support characteristics, the zones corresponding in location with the anticipated loads and loading patterns of a flexible support device in use.

Abstract: A novel support for use with furniture having a spring-edge is provided that includes a coil assembly. The coil assembly is typically square or rectangular with top and bottom surfaces and a front edge that faces the front of the furniture piece. A bridge is secured to the top surface of the coil assembly to provide support for the spring-edge. The bridge extends outwardly away from the front edge of the coil assembly and is supported in the same plane as the top surface of the coil assembly by a series of wires. The wire supports terminate at and hold a stiffening member in place that forms the upper portion of the spring-edge. The stiffening member is used to attach a series of front springs to the bridge. These springs are held in place on their lower end by the frame of the piece of furniture.

Abstract: A low-profile mattress comprises an inner spring core having a plurality of spring coils and having an upper and lower surface. The mattress further includes a padding layer disposed on the upper surface and a quilting layer disposed over the padding layer and having an exterior layer of a liquid resistant material, wherein the innerspring core padding layer and quilting layer are dimensionally adapted to be less than eight inches in height.

Abstract: A coil spring containing mattress comprises a coil spring encased in a sealed container or casing. One or more compressible pads may be included within the casing. Desirably, these pads are of an open-celled foam material which may be compressed in response to applied pressure. Air may be allowed to flow from the mattress to facilitate compression of the mattress and then blocked to assist in maintaining the mattress in a compressed state, for example for shipment.

Abstract: A mattress has a quilted internal pillow wherein one or more internal layers of material are quilt-stitched prior to encapsulation in mattress upholstery. The quilted internal pillow is positioned relative to a support surface of an innerspring or spring core of a mattress to provide support characteristics determined by the quilt stitch pattern. In a related method of manufacture of a mattress with an internal quilt stitched pillow, the layer or layers of the pillow are processed through a quilter stitching machine and then assembled in combination with a mattress spring core and upholstery. The quilted internal pillow may be located adjacent to the spring core, spaced from the spring core by other internal layers of material, or located adjacent to or within a mattress pillowtop, and in each embodiment on one or both sides of the mattress.

Abstract: A mattress is provided having an innerspring, at least one upholstery layer, which includes at least one foam layer, and quilt panel layers. The upholstery layer has an edged support layer, a steel wire grid laminated to the edged support layer, and a firm foam layer laminated to the steel wire grid. The steel wire grid serves to provide support and to reduce the sagging effect caused when adding additional foam layers. The firm foam layer provides support distributed even across the mattress and may be used alone or in combination with the steel wire grid.

Abstract: A mattress with two bands running across its faces to increase firmness and body weight distribution. These bands are composed of panels of a highly resilient material fastened to panels of non-resilient material. The resilient panels are positioned where the greatest load concentrations are likely to be when the mattress is in use. The resilient panels are oriented to stretch in a direction parallel to the major dimension of the band and, as they are stretched, increase in tension in proportion to the load. The greater the load, the greater the tension on the resilient panels and the firmer the mattress becomes in response to the load.

Abstract: A portable diaper changing board for changing a child's diaper on a comfortable and safe surface. The portable diaper changing board includes four support members two of which are end members and two of which are intermediate member which are hingedly attached end-to-end to one another and to the end members with each of the support members having a concave to side and a flat bottom side; and also includes a plurality of fastening members for securing the support members in a folded position; and further includes a restraining member being removeably attachable to the top side of one of the intermediate members for restraining a child thereon; and also includes a handle member securely attached to one of the ends of one of the intermediate members.

Abstract: A bedding or seating product comprising a spring core made up of a plurality of parallel strings of springs joined to each other. Each of the strings of springs comprises a row of interconnected pocketed coil springs. The pocket of fabric surrounding each of these coil springs is divided into at least two subpockets by at least one line of attachment of opposite sides of the fabric to each other. Each of these subpockets contains one portion of the coil spring, thus resulting in a multilayered product.

Abstract: A bedding or seating product comprising a centrally located spring core, edge support means located around the perimeter of the spring core, filling material located above and below the spring core and an upholstered covering. The edge support may be either a string of springs, a pair of spiral edge supports or plastic edge reinforcements. The edge support means extends above and below the upper and lower surfaces of the spring core thus creating a higher peripheral edge than the central portion of the spring core. Layers of filling material are inserted over the central portion of the spring core in order to create a uniform upper and lower surface.

Abstract: A mattress employs a high density, high ILD convoluted polyurethane foam topper as a major transition layer over the supporting surfaces of an innerspring assembly in order to provide a smooth transition from the support characteristics of the padding and upholstery layers to the innerspring assembly. A high density, high ILD foam material of substantial thickness is positioned between a padding or insulating layer over the innerspring assembly and overlying upholstery, with convolutions in the high density transition layer oriented to extend away from the innerspring assembly. The high density transition layer dominates or masks the support characteristics of the innerspring assembly so that the perception of stiffness or board-like feel of an innerspring is greatly reduced upon initial loading of the mattress.

Abstract: A quilt top mattress comprises a spring unit and a cover fabric layer surrounding the spring unit. A quilt top layer overlies the fabric layer. The quilt top layer comprises an outer fabric layer, a fiber batt layer, a convoluted foam cushion and an inner fabric layer, all being secured together by stitching to define a select quilt pattern. The convoluted foam cushion has a planar outer surface in contact with the fiber batt layer, and a convoluted inner surface defined by alternating peaks and valleys, the inner surface facing the spring unit. A fabric flange secures a perimeter edge of the quilt top layer to a corner edge of the cover fabric layer.

Abstract: Apparatus and method for placing a cover or coat on a mattress spring core assembly. The cover has a first cover portion and a second cover portion. Each cover portion is generally padded and has an attached annular skirt for covering the sides of the spring core assembly. The cover portions are fitted with fasteners having hook shaped ends which extend away from the attached cover and protrude inwardly for attaching the top and bottom cover portions to the top and bottom portions of the spring core assembly. After the first and second cover portions are attached to the spring core assembly, the annular skirts are connected together to completely enclose the spring core assembly.

Abstract: A mattress including an innerspring, upholstery topper layers including at least one foam layer, and quilt panel layers. At least one upholstery foam layer includes a firming edge of foam about its perimeter. The firming edge of the upholstery foam layer functions to provide a firmer mattress edge without compromising the thickness of the mattress or requiring additional materials or labor operations during manufacturing.