Abstract: Mattress assemblies include a hybrid posture support system that provide an end user with improved posture support during use, among other advantages. The hybrid posture support system includes a top foam layer including first and second foam portions that are spaced apart and generally correspond to a head/shoulder region and a foot region, respectively, a pocketed microcoil array underlying the top foam layer that is intermediate the first and second foam portions; and an underlying foam layer. The hybrid posture support system can be used in any mattress assembly including mattresses having a coil spring innercore or a foam innercore.

Abstract: Temperature management bedding systems for mattresses and quilt panels generally include a trilayer of active components including a phase change material applied to a top surface of a flexible substrate thereof, a fire retardant layer underlying the flexible substrate including hydrophilic rayon fibers treated with ammonium polyphosphate; and a vertically oriented fiber batting layer underlying the first retardant layer including an elastomeric binder. The temperature management bedding systems provide heat control and mass transfer of moisture from the bedding surface.

Abstract: Flame retardant panels generally include an adaptive cover layer and underlying batting layer. The cover layer includes a moisture vapor permeable synthetic fibrous layer, and a liquid impermeable but moisture vapor permeable thermoplastic layer disposed on an outer face of the cover layer, wherein the liquid impermeable but moisture vapor permeable thermoplastic layer is in an amount of about 2 to 15% by weight based on a total weight of the synthetic fibrous layer and the thermoplastic layer. The underlying batting layer can have a top surface and a bottom surface, the layer comprising a plurality of substantially vertically oriented flame retardant treated fibers extending from the top surface to the bottom surface; and a binder material.

Abstract: Active comfort controlled bedding systems include a variable firmness control and/or variable climate control.

Abstract: Mattress assemblies including static and adjustable mattress foundations generally include a foundation frame including side frame members and transverse frame members attached at respective ends by a corner bracket at each of the respective ends to define a generally rectangular shape. An adjustable support leg coupled to each one of the corner brackets for automatically elevating the foundation frame relative to ground. The adjustable support leg can include an outer tubular member fastened to an interior facing portion of the corner bracket including an end cap, wherein the end cap includes an aperture. A motorized linear actuator can be coupled to the outer tubular member, which can include a motor and an extendible portion coupled to the motor. The extendible portion is configured to selectively retract from and extend through the end cap to change the elevation of the foundation frame relative to ground.

Abstract: Mattress assemblies including static and adjustable mattress foundations generally include a foundation frame including side frame members and transverse frame members attached at respective ends by a corner bracket at each of the respective ends to define a generally rectangular shape. An adjustable support leg coupled to each one of the corner brackets for automatically elevating the foundation frame relative to ground. The adjustable support leg can include an outer tubular member fastened to an interior facing portion of the corner bracket including an end cap, wherein the end cap includes an aperture. A motorized linear actuator can be coupled to the outer tubular member, which can include a motor and an extendible portion coupled to the motor. The extendible portion is configured to selectively retract from and extend through the end cap to change the elevation of the foundation frame relative to ground.

Abstract: Smart response technology mattresses generally includes a sub-core assembly including a self-adjusting, non-powered smart response unit and a polyurethane foam circumscribing a perimeter of the smart response unit and having a thickness equal to or less than a thickness of the smart response unit, wherein the smart response unit comprises a plurality of fluid support cells, wherein each fluid support cell includes an envelope and a reforming element disposed within the envelope; a manifold system including a manifold conduit interconnecting at least two of the fluid support cells, and intake and exhaust valves fluidly coupled to the manifold conduit configured to dynamically open and close in response to a weight load. The mattresses include additional foam layers overlaying the sub-core assembly to define the smart response technology mattresses.

Abstract: A continuous coil string staging system is provided herein that includes at least one coiler configured to output at least one continuous coil string, at least one assembler configured to assemble the at least one continuous coil string into a mattress assembly, and at least one coil string staging apparatus disposed between the at least one coiler and at the least one assembler. The at least one coil string staging apparatus can have an input, a staging buffer, and an output such that the coil string staging apparatus receives the at least one continuous coil string that is output from the at least one coiler and outputs the at least one continuous coil string to the assembler such that there is a buffer of coil string available to the assembler. Various coil string staging apparatuses and methods are also provided herein.

Abstract: An adjustable foundation and process includes a mattress support surface including a head and back section hingedly connected to an intermediate section at one end and a leg and foot section hingedly connected to the intermediate section at another end, wherein the intermediate section includes a first portion and a second portion, wherein the first portion is hingedly connected to the head and back section and the second portion is hingedly connected to the leg and foot section. The intermediate or seat section is configured to increase in length upon articulation of the head and back section 18 and/or the leg and foot section 22 from a flat position or an increase in inclination of any section. Likewise, the intermediate or seat section 20 is configured to decrease in length upon articulation of the head and back section 18 and/or the leg and foot section 22 from an inclined position to a flat position or a decrease in length upon declination of any section.

Abstract: A coil spring mattress and adjustable foundation assembly includes a coil spring mattress; and an adjustable foundation including a mattress support surface including a head and back section hingedly connected to an intermediate section at one end and a leg and foot section hingedly connected to the intermediate section at another end, wherein the intermediate section includes a first portion and a second portion. The intermediate or seat section is configured to increase in length upon articulation of the head and back section and/or the leg and foot section from a flat position or an increase in inclination of any section. Likewise, the intermediate or seat section is configured to decrease in length upon articulation of the head and back section and/or the leg and foot section from an inclined position to a flat position or a decrease in length upon declination of any section.

Abstract: Cushions include a chassis core having a rigid or semi-rigid base sheet; and a plurality of paired flat springs coupled to the rigid or semi-rigid base sheet, wherein each paired flat spring comprises a lower flat spring including a first terminal end, a second terminal end, and a flexible arcuate member extending from the first terminal end to the second terminal end, and an upper flat spring including a first terminal end, a second terminal end, and a flexible arcuate member extending from the first terminal end to the second terminal end, wherein the first and second terminal ends of the upper flat spring are fixedly attached to respective first and second terminal ends of the lower flat spring such that the upper flat spring is inverted relative to the lower flat spring. Also disclosed are processes for manufacturing the core chassis.

Abstract: In many aspects, the systems and methods described herein include mattress assemblies with attached sensory devices. The mattress assembly comprises a mattress core, an attached headboard, a mattress cover at least partially enclosing the mattress core, and at least one customer assistance sensory device attached to at least one of the core, headboard, and cover. The customer assistance sensory device is configured to present at least one parameter of the mattress core or assembly as at least a visual signal. Visual signals may include one or more distinct colors, shapes, or graphic patterns that correspond to one or more parameter of the mattress core or assembly.

Abstract: Mattress assemblies and processes that provide user comfort include at least one thermally conductive foam layer consisting essentially of a polymeric elastomer foam matrix and a plurality of thermally conductive particles disposed therein, wherein the plurality of thermally conductive particles are selected from the group consisting of carbon, graphene, graphite, platinum, aluminum, gold, silver, silicon, copper, iron, nickel, stretched polyethylene nanofibers, and mixtures thereof; and a base core layer, wherein the at least one thermally conductive foam layer overlays the base core layer.

Abstract: An adjustable foundation and process includes a mattress support surface including a head and back section hingedly connected to an intermediate section at one end and a leg and foot section hingedly connected to the intermediate section at another end, wherein the intermediate section includes a first portion and a second portion, wherein the first portion is hingedly connected to the head and back section and the second portion is hingedly connected to the leg and foot section. The intermediate or seat section is configured to increase in length upon articulation of the head and back section and/or the leg and foot section from a flat position or an increase in inclination of any section. Likewise, the intermediate or seat section is configured to decrease in length upon articulation of the head and back section and/or the leg and foot section from an inclined position to a flat position or a decrease in length upon declination of any section.

Abstract: Firmness control for a self-adjusting, non-powered smart response technology mattress includes a body support device; one or more layers overlaying the body support device and a side rail assembly circumscribing a perimeter of the body support device; and the firmness control. The body support device includes a plurality of fluid support cells, wherein each fluid support cell includes an envelope and a reforming element disposed within the envelope; and a non-powered manifold system including a manifold conduit fluidly coupled to at least two of the fluid support cells, and intake and exhaust valves fluidly coupled to the manifold conduit configured to dynamically open and close in response to a weight load. The firmness control includes a pressure relief valve fluidly connected to the manifold conduit via a conduit and configured to selectively permit a controlled amount of fluid flow out from the fluid support cells. Also disclosed are processes for adjusting firmness.

Abstract: A self-adjusting, non-powered smart response technology mattress generally includes an accelerated calibration system comprising a valve fluidly connected to a body support device including a plurality of fluid support cells, wherein each fluid support cell includes an envelope and a reforming element disposed within the envelope; and a non-powered manifold system including a manifold conduit interconnecting at least two of the fluid support cells, and intake and exhaust valves fluidly coupled to the manifold conduit configured to dynamically open and close in response to a weight load. The accelerated calibration system is configured to selectively permit fluid flow out of the fluid support cells in the absence of a weight load upon opening of the valve. Also discloses is a process for releasing excess pressure formed as a result of temperature and barometric pressure changes in the self-adjusting, non-powered smart response technology mattress.

Abstract: Adjustable mattress assemblies and processes including an adjustable mattress foundation dimensioned to support a mattress configured to accommodate two supine users during use thereof includes a foundation frame including a first sub-foundation configured with at least one motorized actuator to effect inclination or declination of the mattress support surface and an abutting second sub-foundation free of a motorized actuator. The second foundation is mechanically coupled to the first foundation such that articulation of the first sub-foundation results in a similar articulation in the second foundation. The first and second foundations have similar length, height and width dimensions, which collectively approximates the size of the oversized mattress configured to accommodate two supine users, e.g., king size, queen size, California king size, or the like.

Abstract: An automated system and process 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.