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: A process and apparatus for manufacturing a mattress generally includes an insertion station for supporting an innercore, a movable platform for supporting a bucket, and an adhesive applicator intermediate the insertion station and the movable platform. The adhesive applicator is configured to apply adhesive prior to or simultaneous with insertion of the innercore unit into a cavity of the bucket. The innercore unit is gravity fed from an elevated surface of the insertion station into a leading edge of the bucket cavity to form the innercore unit and bucket assembly. The process and apparatus minimizes and/or eliminates manual labor as it relates to the manufacture of the innercore unit and bucket assembly.

Abstract: The systems and methods described herein include innerspring assemblies or innerspring cores for use with cushioning articles such as mattresses. The innerspring core may have one or more coil springs formed from a high-carbon steel wire alloyed with one or more suitable alloying elements such as titanium and copper and capable of imparting greater strength and durability to the innerspring core.

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: A plunger matrix mattress includes a number of independently movable foam padded plungers that form an array of independently movable points of support. This type of mattress significantly improves body contouring over conventional coil spring mattress designs. The plunger matrix mattress also allows substantial airflow through the mattress improving over conventional foam mattress designs. Different plungers may have different spring and dampening characteristics to allow different plungers and plunger zones of the mattress to exhibit different firmness levels. Individual plungers may be removed and replaced independently, for example to replace the plunger with another plunger with a different spring characteristic, and make other types of adjustments and repairs.

Abstract: A modular mattress includes several plunger matrix sections that each have a respective plunger matrix support platform. The several sections are configured for side-to-side assembly to form the complete matrix for the mattress. A foldable edge frame snugly receives and houses the plunger matrix sections in side-to-side relation. The edge frame also defines a flange on an internal surface of the edge frame that supports plunger matrix sections in side-to-side relation in a position allowing the plungers to move up and down within an internal space defined by the edge frame. A top pad lays on top of the edge frame and the plunger, while a cover configured encapsulates the edge frame, the plunger matrix, and the top pad into a self-contained mattress unit.

Abstract: The systems and methods described herein include a shell that fits around the mattress of an adjustable bed. The shell may help cover unsightly pivot joints and motors that are part of the adjustable bed. The shell may help hold the mattress in place during the operation of the adjustable bed, or when a user exits or enters the bed. The shell may further help keep the shape of the mattress and prevent the mattress from sagging with time and use. Additionally, the systems and methods described herein include for providing additional features in the shell. Such features may help the user be more comfortable in the adjustable bed, and improve the user's quality of life. These features may be especially useful for patients confined an adjustable bed for prolonged periods of time, such as in a hospital or elderly home care.

Abstract: A foldable mattress includes plunger matrix sections and corresponding flexible connectors connecting the plunger matrix sections in side-by-side relation. The flexible connectors are configured to allow the foldable mattress to fold to adjust in shape corresponding to changes in shape of a mechanically adjustable frame supporting the foldable mattress. The foldable mattress may include a foldable edge frame configured to snugly receive and house the plunger matrix sections in side-to-side relation. The edge frame defines a flange on an internal surface of the edge frame configured to support the plunger matrix sections in side-to-side relation in a position allowing the plungers to move up and down within an internal space defined by the edge frame. A top pad lays on top of the edge frame and the plunger matrix sections. A cover encapsulates the edge frame, the plunger matrix, and the top pad into a self-contained mattress unit.

Abstract: A plunger for a matrix mattress includes a pin guide having a flange and a guide body extending from the flange. A pin slidably received within the pin guide includes a flange located above the flange of the pin guide and a shaft extending from the flange through the guide body. The flange of the pin carries a deformable head. A tension spring has a first end fixed to the guide body and a second end located below the guide body positioned to receive a bottom end of the pin shaft. The spring is configured to resiliently stretch with downward motion of the pin with respect to the pin guide. A dampening device captured around the shaft of the pin between the flange of the pin and the flange of the pin guide resiliently deforms with downward motion of the pin with respect to the pin guide.

Abstract: The systems and methods include a feed mechanism supplying multi-strand wire to a coil-spring winder. The coil spring typically has a plurality of turns and is resilient. The multi-strand wire is typically steel, but may be of other suitable material, or a combination of materials. The coil-spring winder receives wire from a spool of wire and forms that wire into a coil spring. Typically, but not always, the coil-spring winder cuts the coil spring to a desired length, and thereby forms a plurality of coil springs of the type that can be employed in mattresses, furniture, car seats, for industrial machines, or for any other application. To feed the coil-spring winder, the systems include a wire holder that supplies the wire to the coil-spring winder along a feed direction. The wire holder is supported for rotation about an axis that may be aligned with the feed direction. The rotation of the wire holder may be substantially synchronous with the formation of the turns of the coil spring.

Abstract: A mattress assembly includes an inner core comprising a base core layer comprising planar top and bottom surfaces, and at least one comfort layer comprising planar top and bottom surfaces disposed on the top surface of the base core layer; a side rail assembly disposed about a perimeter of the inner core; and a plurality of air channels extending from a central region of the inner core to the side rail assembly configured to permit the flow of fluid from and to the inner core.

Abstract: A mattress comprising asymmetrical coil springs with nonlinear spring rates provides comfort to users with different weights. The lower portion of the spring is cylindrical and the upper portion is conical or frustoconical. This arrangement causes the spring to undergo linear compression before undergoing nonlinear compression. The result is a mattress that is sufficiently soft for lighter users and sufficiently firm for heavier users.

Abstract: A thermally activated display with a temperature management feature and a cover comprising a thermochromic material generally changes from a first color to a second color. The temperature management feature can be a mattress and has a top surface. The cover is substantially flush with the top surface.

Abstract: The systems and methods described herein relate to providing mattresses with foam that is odor-free. Unpleasant odors can be reduced in foam members by including a source of cyclodextrin during the manufacture of foam. Instead of masking odors with fragrances, the systems and methods described herein reduce odors with the aid of, among other things, a cyclodextrin-water solution. In one aspect, a method of manufacturing an odor-free foam for use in a mattress is provided. The method includes solubilizing cyclodextrin in water to form a cyclodextrin solution, and adding the cyclodextrin solution to a reacting mixture of a polyol and a isocyanate to form an odor-free or reduced-odor foam.

Abstract: A dual-spring plunger for a plunger matrix mattress assembly includes an outer tension spring with an upper end fixed to an outer spring mount of a plunger guide body and a lower end located below the guide body positioned to receive a bottom end of a pin of the plunger. An inner tension spring nested within the outer tension spring has an upper end fixed to the inner spring mount of the guide body and a lower end having a spur slidably captured within a slot through a fin of the shaft of the pin. The outer spring is tensioned while the inner spring is not tensioned during a first portion of downward movement of the pin relative to the pin guide, whereas both the outer and the inner spring are tensioned during a second portion of downward movement of the pin relative to the pin guide.

Abstract: A mattress display includes at least one primary test bed including a head portion and a foot portion; at least one secondary test bed including a head portion and a foot portion; a wall, wherein the at least one primary and secondary test beds are in a spaced apart parallel relationship and positioned perpendicular with respect to the wall, wherein the at least one primary test bed is oriented such that the head portion is distally located from the wall and the foot portion 20 is proximal to the wall, and wherein the at least one secondary test bed is oriented such the head portion is proximal to the wall and the foot portion is distal to the wall; and a barrier disposed in close proximity to the head portion of the primary test bed, wherein the barrier is configured to provide an end user of the primary test bed with at least partial privacy, noise reduction, and/or light reduction.

Abstract: Flame retardant panels and methods of manufacture generally include a batting material including a layer having 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: A side rail assembly for supporting an edge of a mattress includes a layer of a polyurethane foam comprising an open cellular structure, wherein the open cellular structure comprises about 10 to about 40 cells per inch, a hardness of about 35 pounds-force to about 100 pounds-force, and a density of about 1.2 pounds per cubic foot to about 2.0 pounds per cubic foot, wherein the layer is configured to be disposed about a perimeter of an inner core of the mattress and is configured to permit the flow of fluid from and to the inner core through the layer.

Abstract: A progressive spring coil comprises a first spring portion comprising a top end and a bottom end and having a first spring rate, wherein the first spring rate is substantially linear or substantially nonlinear; a second spring portion comprising a top end and a bottom end and having a second spring rate, wherein the second spring rate is substantially linear or substantially nonlinear; and a third spring portion disposed between the first spring portion and the second spring portion, wherein the third spring portion has a third spring rate, wherein the third spring rate is substantially linear or substantially nonlinear.