Abstract: A bed construction having a one-sided mattress assembly supported on a rigid foundation. The one-sided mattress assembly includes a core of pocketed coil springs having a layer of resiliently compressible material covering the upper surface thereof and having a bottom surface constructed of a substantially rigid material without a compressible layer. The core of coil springs is attached to the bottom surface around its periphery. The foundation has a rigid inner construction and a noncompressible top layer. The bed construction reduces the amount of compressible padding in the mattress by one-half and consequently the mattress is capable of exhibiting a substantial reduction in the amount of permanent deflection in use.

Abstract: A mattress and a method of manufacturing a mattress are disclosed. The mattress includes a mattress core, a side rail joined to the mattress core by a one or more adhesive patches, optionally a deck applied over an area of the mattress core and joined to the mattress core by adhesive patches, and an upholstery layer defining a sleep surface applied over the deck or the mattress core and joined to the deck by adhesive patches. The adhesive patches have a bonding strength sufficient to maintain a relative position between the various mattress components at least during assembly of the mattress. The upholstery layer is permanently secured to the side rail by, for example, sewing or stapling.

Abstract: A height-adjustable mattress assembly is constructed of a mattress foundation and an optional frame assembly with a plurality of ground support members supporting the mattress foundation. The ground support members can be attached to the frame assembly in at least two orientations so as to maintain the top surface of the foundation above ground in a substantially horizontal orientation at at least two different heights. The mattress foundation can be made of two mattress foundation members that are spaced apart by spacer members. The mattress foundation members can be oriented with respect to each other so as to provide a combined height that is adjustable. By combining the adjustable ground support members with the assembly having two mattress foundation members, adjustment at three or more different heights is possible.

Abstract: A spring assembly including a helical coil formed from a multi-strand cord.

Abstract: A bed assembly provides an enlarged sleeping surface area as compared to a standard Queen sized bed. Specifically, in the disclosed bed assemblies, the sleeping surface area is about 64 inches to about 68 inches wide and about 77 inches to about 82 inches long. This can be accomplished by providing both a mattress and a foundation having the appropriate, enlarged sleeping surface area, or by combining an enlarged mattress with a foundation having at least one standard Queen sized surface. The mattress and foundation can be fit into a bed frame made of a suitable size to fit the bottom surface of the foundation (i.e., either “enlarged” or standard Queen size). The enlarged sleeping surface of the bed may be between about 65 inches to about 67 inches wide and about 78 inches to about 80 inches long. This enlarged sleeping surface area provides a more comfortable and restful sleep for two occupants.

Abstract: A mattress having an inverted top panel/border seam, with an optional appended decorative rope welting on the border is described. An inverted seam secures the top panel to the border portion of a mattress cover to eliminate bumps and creases found in conventional welted top seam. Manufacturing costs may be reduced by eliminating the need for an expensive table-mounted tape edge closure machine and/or skilled operators, since the inverted seam may be flay sewn with a conventional sewing machine or even hand-stitched. Alternatively, a conventional tape edge machine can be used with less-skilled labor and or reduced tape/welting material, as all of the stitches and welting are hidden inside the mattress by the inverted seam.

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 stiffening system for the perimeter edges of a foam core mattress comprising a coil spring (or other spring-based) structure disposed along one or more perimeter edges (e.g., one or both side edges, the foot, the head, or a combinations thereof including the foot and both side edges) of a mattress having a foam sleeping area. The perimeter spring structure is rectangular or square in cross-section and provides sufficient stiffness for comfortable seating on the edges of the mattress and is joined to the foam core by planar fabric elements that span the joint between them and are attached to both. The sleep area provides the softness and other salutary effects of a foam sleeping surface while the stiffer spring perimeter element provides the rigidity need for comfortable seating and wear resistance.

Abstract: A mattress having an inverted top panel/border seam, with an optional appended decorative rope welting on the border is described. An inverted seam secures the top panel to the border portion of a mattress cover to eliminate bumps and creases found in conventional welted top seam. Manufacturing costs may be reduced by eliminating the need for an expensive table-mounted tape edge closure machine and/or skilled operators, since the inverted seam may be flay sewn with a conventional sewing machine or even hand-stitched. Alternatively, a conventional tape edge machine can be used with less-skilled labor and or reduced tape/welting material, as all of the stitches and welting are hidden inside the mattress by the inverted seam.

Abstract: A versatile support member constructed of a metallic mesh is provided in a bedding product. The support member is placed on top of the mattress core (whether foam or spring coil) before the mattress cover is attached. The support member may be constructed of titanium wire in a woven or welded mesh grid or web configuration, although other metals (such as, but not limited to, vanadium, chromium, platinum, molybdenum, nickel, iron, zinc), alloys thereof, or fiber composites (such as, but not limited to, carbon or graphite) may be used. The support member may be directly attached to the core or may be secured to the upper or lower border rods by hog rings, stitching, lacing, or other conventional means.

Abstract: A stiffening system for the perimeter edges of a foam core mattress comprising a coil spring (or other spring-based) structure disposed along one or more perimeter edges (e.g., one or both side edges, the foot, the head, or a combinations thereof including the foot and both side edges) of a mattress having a foam sleeping area. The perimeter spring structure is rectangular or square in cross-section and provides sufficient stiffness for comfortable seating on the edges of the mattress and is joined to the foam core by planar fabric elements that span the joint between them and are attached to both. The sleep area provides the softness and other salutary effects of a foam sleeping surface while the stiffer spring perimeter element provides the rigidity need for comfortable seating and wear resistance.

Abstract: Presently disclosed is a mattress cover that has marked upon it outlines of the various sizes of mattresses available for sale for use a sizing gauge or selling aid. A conventional mattress cover may be printed or embroidered with lines representing the various sizes of all of the mattresses sold by that manufacturer. Thus, the manufacturer may outline on the cover the external dimensions of smaller mattresses. The lines representing the different mattress sizes may, in one embodiment, be printed on the fabric of the cover through conventional printing means prior to final assembly and quilting of the cover. In a further embodiment the lines may be embroidered or embossed either before or after assembly of the cover.

Abstract: An apparatus and method for winding strings of pocketed coils onto a spool. The coil spooling apparatus includes a feed mechanism and a spooler. The feed mechanism includes buffer rollers and an adjustable hollow feed arm. The feed arm terminates adjacent to the spooler. The spooler includes a spool with a horizontally or vertically oriented spool core, a drive mechanism, and a turntable base with a pallet. The drive mechanism powers the rotation of the spool core. The rotation of the spooler winds the string of pocketed coils received from the feed mechanism. The feed mechanism buffers the tension and directs the string of pocketed coils along the horizontal and vertical axis. After the desired size of wound package is reached, the rotation of the spooler ceases. The completed wound package can then be lifted while attached to the spool through the use of a fork lift. The vertical spools can be stored and transported in a vertical position since the core base is flat.