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: Systems and methods described herein relate to a sleep diagnostic system including a mattress assembly, a plurality of sensors, data acquisition circuitry, an input device, a sleep processor, and a display device. The mattress assembly may have a sleeping surface, and the plurality of sensors may be disposed within the mattress assembly below the sleeping surface. The sensors are configured to measure at least one sleep condition and output data signals indicative of the sleep condition. The sleep processor receives signals from both the sensors and one or more other input devices, and determines a sleep characteristic based upon these received signals. The display device, which includes circuitry and a graphical user interface, receives the sleep characteristic from the sleep processor and displays it to the user.

Abstract: Mattresses including a polymeric contact sensor configured to provide real-time dynamic contact information, which can then be used to report sleep quality, body position and/or pressure distributions to the user. The polymeric contact sensors could also be used to control parameters of the mattress and/or foundation with adjustable firmness for a given position and/or body shape/type/size. The polymeric contact sensor includes a plurality of flexible strips formed of a polymeric material and a conductive filler, wherein the polymeric contact sensor is in electrical communication with a data acquisition terminal, wherein the polymeric contact sensor is disposed on or within the upholstery layer, or on or within the quilt layer, or on a top surface of the innercore unit.

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: 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.

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: The mattress assemblies have an array of springs extending from a sheet. Each spring in the array may be manufactured by choosing a position for the spring, cutting a profile of the sheet spring in the sheet, peeling back or bending the profile or tab of the sheet, and shaping the profile to form the sheet spring. The array of springs may be formed from creating a plurality of such springs along rows and columns. In certain embodiments, multiple sheets may be stacked to form the sheet spring array.

Abstract: Mattresses and methods for processing a flexible foam material for use in a mattress to provide a mattress foam material that has more consistent firmness over time and area. The methods include pre-conditioning the foam pad or mattress by applying a force across a substantial portion of a major surface of the mattress to compress or stretch the height of the foam, the length of the foam, and/or the width of the foam to break or open closed cells. In certain embodiments, the force is applied by repeatedly pressing a platen against the foam pad or placing the foam pad between one or more rollers.

Abstract: An apparatus and process for measuring recovery rate and total recovery time of viscoelastic foam samples. This apparatus will record the change in height with time to fully define how a viscoelastic foam responds to compression. The process generally includes compressing a compression plate against a surface of the viscoelastic foam sample from a nominal height to a pre-determined compressed height, maintaining the pre-determined compressed height for a period of time; retracting the compression plate at a rate greater than a recovery rate so as to disengage the compression plate from the viscoelastic foam sample, and measuring displacement as a function of time to provide a viscoelastic response profile. Measuring the displacement may be contact based or non-contact based.

Abstract: A point-of-sale demonstration system includes a display system for viewing the underside of the plunger matrix mattress allowing a person sitting or lying on the mattress to readily view the impression created by their body weight on the plungers. The display system includes a camera positioned to image the underside of the mattress and a monitor (display screen) positioned for viewing by a person lying on the mattress so that they can see the deflection in the bottom of the plungers caused by their own weight on the mattress. Seeing the image of the downwardly displaced plungers immediately conveys the operation of the plunger matrix mattress to the viewer. The system may also be configured to capture individual frames and video images, store the images, transmit the images, and edit as desired, for example by zooming, cropping, changing the speed of the video, and so forth.

Abstract: A smart pillow unit and processes for providing active noise cancellation and biofeedback.

Abstract: A process and apparatus for manufacturing a mattress generally includes an insertion station for applying an adhesive and inserting an innercore unit to a bucket to form an innercore unit/bucket assembly.

Abstract: Systems and methods include a spring-coil assembly having non-linear load-deflection characteristics that are substantially similar to foam. In particular, the systems and methods described herein include a first set of encased springs that are in a partially compressed state and a second set of shorter springs. These two sets of springs may be arranged in alternating rows such that the resulting spring-coil assembly displays non-linear load-deflection characteristics similar to foam.

Abstract: Systems and methods described herein relate to a sleep diagnostic system including a mattress assembly, a plurality of sensors, data acquisition circuitry, an input device, a sleep processor, and a display device. The mattress assembly may have a sleeping surface, and the plurality of sensors may be disposed within the mattress assembly below the sleeping surface. The sensors are configured to measure at least one sleep condition and output data signals indicative of the sleep condition. The sleep processor receives signals from both the sensors and one or more other input devices, and determines a sleep characteristic based upon these received signals. The display device, which includes circuitry and a graphical user interface, receives the sleep characteristic from the sleep processor and displays it to the user.

Abstract: Systems and methods described herein relate to a sleep diagnostic system including a mattress assembly, a plurality of sensors, data acquisition circuitry, an input device, a sleep processor, and a display device. The mattress assembly may have a sleeping surface, and the plurality of sensors may be disposed within the mattress assembly below the sleeping surface. The sensors are configured to measure at least one sleep condition and output data signals indicative of the sleep condition. The sleep processor receives signals from both the sensors and one or more other input devices, and determines a sleep characteristic based upon these received signals. The display device, which includes circuitry and a graphical user interface, receives the sleep characteristic from the sleep processor and displays it to the user.

Abstract: A staging cart for moving multiple packaged mattresses generally includes a base frame having a length and a width dimension; a handle frame extending upwardly from a rear end of the cart; a pair of rear wheels and a pair of forward wheels mounted to a bottom surface of the base frame at the rear and forward ends of the base frame, respectively; a platform portion coupled to the base frame spanning a length of the base frame and having a planar surface, wherein the platform portion has a width dimension less than the width dimension of the base frame and is medially located within the base frame; and at least one roller coupled to the base frame spanning the length dimension and adjacent to at least one side of the platform portion, wherein the at least one roller has an axis of rotation parallel to the longitudinal axis of the platform portion.

Abstract: The support characteristics within a foam mattress body may be varied by inserting reinforcements into channels cut or otherwise formed within the foam.

Abstract: Mattress packaging displays and the display containers for displaying one or more mattresses in a retail environment generally include a bottom panel, a top panel, sidewalls extending from the bottom panel to the top panel, a front facing panel, and a rear facing panel; wherein the container is seated on the bottom panel during display and comprises at least one opening exposing at least a portion of the mattress, and wherein the container is configured to contain the mattress.