Abstract: A mattress provides side support that reduces the likelihood that a person will accidentally roll off and also provides increased comfort to a person sitting on the side of the mattress. The mattress includes a top layer, a bottom layer and a buffer layer between the top and bottom layers. A pair of support members are placed in corresponding cavities near the opposite sides of the top layer. The support members are firmer than the top layer and are arranged to support the top layer and provide reduced compression of the mattress when a weight is placed on the upper surface of the top layer near the support members.

Abstract: An attachment gusset with ruffled corners and method and machinery for manufacture provides a gusset formed of a continuous strip of material which is pleated at corners or turns in direction of the gusset to form ruffles which are attached to an adjacent layer of material. The ruffled gusset lies substantially flat against adjacent layers of material to which it is attached in a pressed state, and can be expanded to accommodate dimensional structures, such as cushioned pads. The number and spacing of pleats can be adjusted according to the radius of the corners or turns in the gusset. In a method of construction of the gusset, the pleats are formed as the material to which the gusset is attached is turned relative to the sewing point of attachment.

Abstract: A mattress border assembly and method for preparing foam rails for shipment prior to assembly to form a mattress border assembly are disclosed. Strips of double-faced, high strength acrylic adhesive tape are applied to at least portions of the end walls of two foam rails. The second adhesive surface of the tape is covered with a protective liner until the border is to be assembled. When assembled, the end walls of the two foam rails are adhered with the tape to side walls of two other foam rails to form a generally rectangular frame structure that comprises the mattress border assembly. Optionally, additional strips of double-faced, high strength acrylic adhesive tape are applied to portions of the top walls and portions of the bottom walls of the foam rails so that additional mattress components may be adhered thereto.

Abstract: A mattress is provided for use with a bed deck having a recess. The mattress includes a mattress section configured to define a patient rest surface and a mattress section support configured to support the mattress section.

Abstract: A mattress comprises a cover defining an interior region, a first foam section located in the interior region of the cover, and a second foam section located in the interior region of the cover adjacent the first foam section. The first foam section includes a first angled surface and the second foam section includes a second angled surface configured to abut the first angled surface.

Abstract: A mattress including (a) an innerspring, (b) one or more upholstery topper layers including an edge support that is a foam construction with at least two foam layers, and (c) one or more quilt panel layers. The at least two foam layers form the edge support or firming perimeter edge, wherein the first foam layer has (1) a defined firmness, (2) a thickness greater at its perimeter, and (3) a central portion forming a receiving space. The second foam layer has a defined firmness less than the first foam layer and is nestably insertable into the receiving space of the first foam layer. The firming perimeter edge functions to provide a firmer mattress edge without compromising the thickness of the mattress or requiring additional materials or labor during manufacturing.

Abstract: A composite mattress is comprised of a rectangular intermediate base with four upper sidewalls extending vertically above the base adjacent the edges of the base forming an upper cavity, four lower sidewalls extending vertically below the base adjacent the edges of the base forming a lower cavity, a spring mattress comprised of a plurality of coil springs individually encased within material pockets positioned in the lower cavity below the base, an air mattress comprised of a plurality of adjustable air cell units formed with independent air cells positioned in the upper cavity above the base, and a cover encasing the entire composite mattress.

Abstract: A mattress includes a cover defining an interior region and a plurality of foam modules located in the interior region of the cover. Each of the plurality of foam modules is separately removable from the interior region and has a central foam portion and first and second side foam portions coupled to and extending along opposite sides of the central foam portion to provide a module width dimension substantially equal to the width dimension of the mattress.

Abstract: Extruded foam reinforcement pieces are described for assembly in connection with innerspring assemblies and mattresses. The pieces have optimized cross-sectional configurations which can be consistently extruded in continuous strands which are then cut to length according to the type and size of innerspring assembly. The pieces are configured to engage various components of the innerspring, including spring coils, spaces between spring coils, and framing borderwires. The foam reinforcement pieces facilitate attachment and alignment of overlying material such as padding and upholstery and function to improve the support characteristics of an innerspring.

Abstract: A mattress system includes a first section of foam material forming the head section of a mattress, a second section of foam material forming, the central section of the mattress, and a third section of foam material forming the foot section of the mattress. The second section of foam material has a load responsive characteristic different from the load responsive characteristic of the first and third sections. The central section may be replaced by an inflatable air chamber.

Abstract: A patient support system is provided with side bolster features for improved patient safety and control. A multi component mattress includes a resilient foam core having associated therewith two side bolsters of a less compressible resilient material. Each side bolster forms two peaks with a saddle therebetween to prevent a patient from rolling off the mattress while still providing direct entry and exit access to the mattress. A foam topper may be applied across the top of the exposed core and the upper portion of the side bolsters. Such topper may include parallel ridges, as well as perpendicular segmentations to improve pressure dispersion. The total coverage topper or upper layer surface adds to usable patient support area for the mattress while otherwise minimizing the pressure from the less compressible bolster elements.

Abstract: A mattress having an anti-roll off feature is disclosed. The mattress has an innerspring unit having an array of coiled compression springs separating opposed parallel surfaces, wherein the surfaces are covered by a webbing made of a nonwoven polypropylene, and wherein the outer periphery of the webbing has horizontally disposed rigid foam planks wrapped and held in place by the webbing. The foam planks are formed from polyethylene foam. Additionally, vertically disposed rigid polyethylene foam planks with cross members are situated within the innerspring unit between the compressions springs at the periphery of the innerspring unit. The foam planks with cross members provide the support needed to achieve the anti-roll off feature. In an alternative embodiment, rigid polyethylene foam cylinders are placed within the rows of compression springs at the periphery of the innerspring unit to provide support at those locations.

Abstract: A side bolster system is provided for use with a mattress having a first side and a second side. The side bolster system of the present invention includes a first side bolster configured to be positioned along the first side of the mattress, a second side bolster configured to be positioned along the second side of the mattress, and a transverse tether having a first end coupled to the first side bolster and a second end coupled to the second side bolster.

Abstract: Multiple varieties of patient support surfaces are presented with a common modular assembly primarily including a perimeter chassis and integrated upper support element. Perimeter bolsters provide relatively firmer support for gently prompting a patient towards the center of the bed, without obstructing regular entry and egress. The added stability facilitates safer transfers and better sitting at the edge of the bed. Pressure redistribution air cylinders (turned either longitudinally or laterally) are captured by shaped, slotted inner bolsters aid underside arches of an integral foam topper. All such features work collectively to cradle and surround the air cylinders. The resulting interlocking, integrated design provides flexible progressive support while maximizing structural integrity. Different arrangements of air cylinders and static or dynamic performance thereof, either non-powered or powered, permit different embodiments to be created using the same modular assembly approach.

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 corner guard configured to attach to and protect the corner of a mattress foundation, as well as to receive selected ornamentation. The corner guard includes an impact-resistant core and a cover that overlies at least at portion of the core. In one embodiment of the invention, the cover is constructed of fabric and may be ornamented with patterns or indicia by a variety of techniques. The cover ensures that the ornamentation will not be damaged even if the corner guard must be bent to match the shape of the mattress foundation. Optionally, a foam layer may be positioned between the core and the cover to impart a quilted texture and appearance to the corner guard, and to provide additional padding for the mattress foundation.

Abstract: A sleeper sofa incorporating an air mattress including a telescoping mattress frame for supporting a mattress support subassembly consisting of hinge panels. The hinges used to connect the panels limit the angular range of motion of adjacent panels to plus or minus 90.degree. from a coplanar arrangement. The "panel" that defines the seating surface on which seat cushions rest when the sofa is in the seating position may be supported in the seating position by a pair of side rails that lack significant structure in the seating plane. This "panel" may also include a set of sinuous springs clad in padding similar to the seat-cushion support surface of a conventional non-sleeper sofa. The air mattress used in the sleeper sofa can be a multi-chamber design in which the outer edges of the mattress are inflated to a higher pressure to prevent the user from rolling off the edge of the mattress.

Abstract: A mattress assembly comprising an innerspring, a top mattress cover over the upper surface of the innerspring, a bottom mattress cover over the lower surface of the innerspring, layers of insulating and cushioning material sandwiched between the mattress covers and innerspring, and a peripherally extending border strip around the entire periphery of the mattress assembly between the peripheral edges of the top and bottom mattress covers which is releasably secured in place, whereby the border strip can be readily unfastened and removed for access to inner portions of the mattress assembly for inspection and repair. When in place, the releasable border strip of this invention appears to be permanently connected to the peripheral edges of the top and bottom mattress covers and an extension thereof.

Abstract: A pad for preventing patient entrapment between a mattress supported by a bed frame and a bed rail movable with respect to the bed frame. The pad includes an elongate rail side opposite an elongate mattress side, a frame bottom connecting bottom edges of the rail side and the mattress side, a corner connecting the mattress side to the frame bottom, and at least one pair of elastic straps extending from the corner. Each distal end of each elastic strap is detachably securable to the other distal end and the pair of elastic straps are securable around either the bed frame or the bed rail.

Abstract: A mattress system includes a first section of foam material forming the head section of a mattress, a second section of foam material forming the central section of the mattress, and a third section of foam material forming the foot section of the mattress. The second section of foam material has a load responsive characteristic different from the load responsive characteristic of the first and third sections. The central section may be replaced by an inflatable air chamber.

Abstract: An anti-decubitus pneumatic mattress adapted to replaceably overlay a conventional mattress of a bed and have a patient move in preselected ways so as to prevent the patient from having skin breakdowns, and from falling off the bed when the patient is turning, and from bottoming out on a low side of the turning, while being suspended in a cushion of static air, if power to the anti-decubitus pneumatic mattress fails. The mattress includes a main assembly, a pair of bolsters, and a bottom assembly. The main assembly is adapted to overlay the conventional mattress of the bed, and has opposing longitudinal sides, and comprises a plurality of cells that are selectively inflatable for moving the patient in the preselected ways so as to prevent the patient from having the skin breakdowns.

Abstract: An edge support spring and handle structure is provided for use in mattresses comprising a continuous length of wire bent to have an elongated top portion and a pair of transverse arms extending downwardly and inwardly from the ends of the top portion, and a bottom portion that mirrors the top portion, with each pair of mirrored transverse arms meeting in a loop to form a pair of loops to which a pair of inwardly extending members of a handle attach. The handle is constructed to have an elongated portion for gripping outside the mattress cover and inwardly extending members that attach to the loops in the edge support spring, such that any strain created by use of the handles will be directed to the edge support spring.

Abstract: A method of manufacture and formation of mattress foundation corner guards made of formable metal, including the steps of manufacturing guards in a flat planar configuration with attachment tabs extending from a bottom edge of the sidewall and in the same plane as the sidewall, and forming the guard about the rounded corner of a mattress foundation by positioning the sidewall of the guard at a midpoint of a radiused corner of intersecting side walls of a mattress foundation and the bending the side wall to generally conform to the radiused vertical wall of the mattress foundation corner, whereupon the corner guard side wall remains in a curved configuration which generally conforms to the radiused corner, and bending the attachment tabs about a bottom edge of the mattress foundation to lie flush against a bottom surface of the mattress foundation, and fastening the attachment tabs to the bottom of the foundation.

Abstract: A corner guard for reinforcing an edge or corner of a mattress of a bed is disclosed. The corner guard is constructed from a flat sheet of material formed into two flat panels intersecting to define a 90 degree primary angle, wherein the panels together further define interior areas facing the mattress and exterior areas facing away from the mattress. Each panel has a tab extending therefrom at right angles toward the interior. Each tab also has a fin extending therefrom toward the primary angle. Fastener openings are provided in each fin and tab. At the intersection of the base of each fin, tab, and panel is a circular cut-out. The corner guard can be punched and formed from metal or molded from polymer.

Abstract: The multi-layer mattress provides a separation sheet, for example, made of plastic or cloth, between foam layers to allow them to better flex and compress separately.

Abstract: An elongated mattress core for a mattress structure includes a foam core having an upwardly-facing top surface, a bottom surface spaced apart from the top surface, and first and second elongated sides connecting the top and bottom surfaces. The foam core is formed to include a plurality of longitudinally spaced apart transverse slits extending downwardly from the top surface. Each slit terminates at a lower end spaced apart from the bottom surface by a first distance and extending transversely from a first slit end spaced apart from the first side of the foam core to a second slit end spaced apart from the second side of the foam core. Each adjacent pair of slits defines a foam column so that the foam core has a plurality of longitudinally spaced apart and transversely extending foam columns. Each foam column has a pair of generally vertical column side walls defining the slits.

Abstract: Internal mattress wall structures interlockingly engageable with mattress innerspring assemblies provide a structurally integrated resilient mattress support edge to which the mattress padding and upholstery is integrally attached. The wall structures include a main body section with a vertically oriented wall surface and a plurality of parallel flanges which mechanically engage the innerspring assembly by compression fit between the intermediate and terminal convolutions of the perimetrical coils of the innerspring assembly. Corner structures contiguous with side and end wall structures form a contiguous smooth side wall with support characteristics comparable to an innerspring 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.

Abstract: A mattress having a core section of latex foam rubber at least partially surrounded by border sections of synthetic urethane foam having substantially the same thickness as the core section. The synthetic border sections are adhesively attached to the periphery of the core section. The mattress can be used as a mattress topper as well as a full mattress.

Abstract: A pressure relief valve vent line mattress system utilizes a self-adjusting approach with a single air source to obtain in combination a low air loss feature for beneficial cooling and drying of a patient's skin. A single air supply source outputs a predetermined positive flow of air into one or more patient air support bladders. An air distribution manifold received within a mattress body receives and disperses overflow pressure routed thereto from the patient air support bladders via an air passageway having a first pressure relief valve with an established set point. A second pressure relief valve is associated with a pump return line adjunct to the constant air flow pump. The net effect is to disperse overflow pressure from the mattress bladders (tending to keep such bladders at a constant pressure) while providing low air loss through the mattress for patient cooling and drying effects, all utilizing a single air flow source.

Abstract: A mattress assembly designed to allow passive air to flow through the mattress and away from a baby. The mattress assembly includes a lightweight frame member with openings on all four sides and a breathable slip-on mattress cover which fits snugly over the frame. An infant is positioned upon the mattress over the bed frame opening, thereby allowing the air to pass through the breathable mattress cover.

Abstract: A foldable bed is movable between an unfolded position, in which interconnected seat, cavity, and body sections are substantially horizontally aligned and of substantially uniform depth, and a folded position, in which the body section is horizontally disposed, the seat section is horizontally disposed and overlies said body section, the cavity section is generally upright and extends between the body and seat sections. In the folded position, the seat section of the mattress is collapsible, and the cavity section of the mattress is noncollapsible. The bed frame can include a leg that is spaced away from the frame in the folded position that compresses a mattress head section, thereby forming a space within which collapsible springs of the seat section can reside. The bed can include springs having upper, intermediate, and lower runs, wherein the upper and lower runs include offset portions extending in opposite directions that are generally orthogonal to a plane defined by the spring intermediate run.

Abstract: A mattress with an inflatable bladder and an outer border wall to support the outer edges of the bladder. The present invention employs foam block border walls that include foam border elements with either an upper or an upper and a lower surface sculpted to present convolutions preferably having generally sinusoidal shapes in vertical cross-section. The convolutions allow for a sensation of softness when being deformed, and allow for ventilation of the inner surface, while at the same time, the foam element can be made of a single piece of foam that is of sufficient stiffness to support the outer perimeter surface of the bladder within the mattress.

Abstract: A futon mattress construction including at least one end cap formed of a flexible, deformable material that is resistant to flattening, a means for retaining the end cap near an edge of the mattress and at least two layers of batting encasing the flexible, deformable members and enclosed in a protective cover is disclosed. A method of manufacturing the futon mattress is also disclosed.

Abstract: A protective and decorative mattress foundation curved corner guard is mold formed in a curved configuration with a wall portion of the guard having a radius of curvature approximately equal to a radius of curvature of rounded corners of a mattress foundation to which the corner guard is to be attached. Raised areas in the form of indicia are mold formed to protrude from a front surface of the curved wall. Edges of the raised areas are bevelled to allow mold pieces to be withdrawn from the front surface of the curved wall without damage to the molded guard. When mold formed of a suitable plastic material, the curved corner guard, including the curved wall and raised indicia thereon, can be metal plated and polished.

Abstract: An elongated mattress core for a mattress structure includes a foam core having an upwardly-facing top surface, a bottom surface spaced apart from the top surface, and first and second elongated sides connecting the top and bottom surfaces. The foam core is formed to include a plurality of longitudinally spaced apart transverse slits extending downwardly from the top surface. Each slit terminates at a lower end spaced apart from the bottom surface by a first distance and extending transversely from a first slit end spaced apart from the first side of the foam core to a second slit end spaced apart from the second side of the foam core. Each adjacent pair of slits defines a foam column so that the foam core has a plurality of longitudinally spaced apart and transversely extending foam columns. Each foam column has a pair of generally vertical column side walls defining the slits.