Abstract: Hybrid coil and air chamber assemblies for cushioning supports generally include pressurized air chambers that are positioned intermediate strings of pocketed coils. In this manner, the coils and air chambers can move independently but can be made to cooperate to provide firmness control, contouring and/or support of a user thereof. Air pressure within the air chambers can be independently adjusted to manipulate firmness and/or contour properties in specific zones defined by the presence and location of the air chambers, e.g., pressure of the air chambers corresponding to the lumbar region can be adjusted to eliminate high pressure points. Still further, the pressure within the air chambers can be automatically adjusted to different applied loads as a function of movement. Also disclose are processes for adjusting a mattress including the hybrid coil and air assemblies.

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

Abstract: Adjustable mattress foundations generally include a mattress support surface including a head and back section hingedly connected to an intermediate seat section at one end and a leg and foot section hingedly connected to the intermediate seat section at another end. The intermediate seat section includes spaced apart upper and lower panels, wherein the lower panel is hingedly connected to the head and back section and slideably engaged with side frame members of the foundation, and wherein the upper panel is stationary and hingedly connected to the leg and foot section. A linear actuator is operatively coupled to a linkage assembly to independently effect inclination or declination of the head and back section relative to the intermediate seat section and is further operative to effect an increase or decrease in a length of the intermediate seat section by movement of the lower panel relative to the upper panel.

Abstract: A process and apparatus 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.

Abstract: Disclosed herein methods for scheduling the automated manufacturing of mattresses. Aspects include receiving a plurality of customer orders for mattresses, wherein each of the plurality of customer orders includes a due date and organizing the plurality of customer orders into production batches based on the due dates. Aspects also include analyzing a first production batch of the daily production schedule and responsively creating an optimized hour production batch and based on a determination that the optimized first production batch exceeds a performance threshold 1, dispatching the first hourly production batch to an automated manufacturing system for production. Based on a determination that the optimized first hour production batch does not exceed the performance threshold, aspects further include analyzing a second production batch and modifying the optimized first production batch and the second production batch to create an optimized second production batch.

Abstract: Mattress assemblies that provide increased user comfort and increased airflow. The mattress assemblies generally include a multilayered mattress core including at least one coil spring layer disposed on and in direct contact with a viscoelastic foam layer.

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: A process and apparatus 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.

Abstract: Hybrid coil and air chamber assemblies for cushioning supports generally include pressurized air chambers that are positioned intermediate strings of pocketed coils. In this manner, the coils and air chambers can move independently but can be made to cooperate to provide firmness control, contouring and/or support of a user thereof. Air pressure within the air chambers can be independently adjusted to manipulate firmness and/or contour properties in specific zones defined by the presence and location of the air chambers, e.g., pressure of the air chambers corresponding to the lumbar region can be adjusted to eliminate high pressure points. Still further, the pressure within the air chambers can be automatically adjusted to different applied loads as a function of movement. Also disclose are processes for adjusting a mattress including the hybrid coil and air assemblies.

Abstract: A process and apparatus 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.

Abstract: Adjustable mattress foundations generally include a mattress support surface including a head and back section hingedly connected to an intermediate seat section at one end and a leg and foot section hingedly connected to the intermediate seat section at another end. The intermediate seat section includes spaced apart upper and lower panels, wherein the lower panel is hingedly connected to the head and back section and slideably engaged with side frame members of the foundation, and wherein the upper panel is stationary and hingedly connected to the leg and foot section. A linear actuator is operatively coupled to a linkage assembly to independently effect inclination or declination of the head and back section relative to the intermediate seat section and is further operative to effect an increase or decrease in a length of the intermediate seat section by movement of the lower panel relative to the upper panel.

Abstract: Height adjustable mattress assemblies generally include a foundation frame including side frame members and transverse frame members attached at respective ends by a corner bracket to define a generally rectangular shape. A deck is supported by the foundation frame and adjustable support legs are coupled to each one of the corner brackets. Each of the adjustable support legs includes an outer tubular member fastened to an interior facing portion of the corner bracket and a differential driven linear actuator including an extendible portion. The assemblies further include a single or dual actuator assembly mechanically engaged with the differential driven linear actuators in each one of the adjustable support legs to extend or retract the extendible portion so as to change an elevation of the foundation frame relative to ground upon actuation thereof. Also disclosed are processes for adjusting a height of a mattress assembly.

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: Mattresses including a chassis core including a rigid or semi-rigid base sheet; a plurality of flat springs spaced apart from one another in parallel rows, wherein each one of the plurality of flat springs comprises 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 wherein a center of an arc defined by the arcuate member is fixedly attached to the rigid base sheet; a body support disk disposed on each one of the first and second terminal ends. The body support disk supports the load of an individual. In some embodiments, the body support disk is pivotably connected to each terminal end.

Abstract: A method for viewing an augmented reality product brochure for a mattress product on a computing device is provided. The method includes capturing an image corresponding to the mattress product with a camera of the computing device and retrieving the augmented reality product brochure corresponding to the image from a memory of the computing device. The method also includes displaying the augmented reality product brochure on a user interface of the computing device, wherein the augmented reality product brochure includes a representation of the mattress product and modifying the representation of the mattress product based on receiving one or more instructions from the user.

Abstract: Active noise control systems, devices, and methods are disclosed herein. Anti-snoring systems can include a first pillow unit having at least one error microphone and at least one speaker, at least one reference microphone configured to capture sound produced proximate to the at least one reference microphone, and a control unit operatively coupled to the first pillow unit and the at least one reference microphone. In some aspects, the control unit can be configured to produce an anti-noise in the at least one speaker disposed in the first pillow unit by processing signals received from the at least one error microphone and the at least one reference microphone using gated dynamic adjustments such that the anti-noise cancels any sound produced proximate the at least one reference.

Abstract: Cushioning articles such as mattresses can include a three dimensional wave spring core. The wave spring includes a polymeric lattice spring structure including a plurality of alternating layers stackedly arranged to define a height of the wave spring, wherein each one of the alternating layers is defined by a single strand having one or more upward and downward undulations, wherein the alternating layers are arranged such that an upward undulation of one layer is connected to a downward undulation of the other layer to define a cell configured to receive a compressive force, wherein the lattice structure has a sinusoidal shape when viewed top down and is configured to have three dimensional structure.

Abstract: A process and apparatus 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.

Abstract: A climate controlled bedding system includes at least one coil spring layer; and an air supply fluidly coupled to the one or more fluid conduits. In some embodiments, a filter is disposed within a flow path of a fluid conduit.