Abstract: A pocket spring mattress for use in a bedding or seating product is disclosed. The mattress comprises a plurality of interconnected coil springs enclosed in continuous covers forming strings of pockets accommodating the coil springs. Adjacent coil springs within each string are spaced apart by an interjacent separation distance, said separation distance exceeding at least 20 percent of the diameter of the largest one of the spiral turns of the adjacent coil springs. Further, the pocket spring mattress further comprises a cushioning pad located above the upper end of each coil spring, wherein the covers provides first compartments enclosing the coil springs, and second compartments enclosing the cushioning pads, said first and second compartments being separated from each other. The cushioning pads each have a length extension in the longitudinal direction of the strings exceeding the diameter of the largest one of the spiral turns of the corresponding coil spring.

Abstract: A pocket-spring core having at least one first zone and at least one second zone, wherein the first zone has at least two rows of a first spring portion and at least one of the second zones has at least one row or line of a second spring portion, wherein the second spring portion has at least two layers which are located vertically one above the other and comprise in each case a plurality of helically wound first compression springs, in a first, upper layer, and second compression springs, in a second, lower layer, and at least one row of a third spring portion, is distinguished in that at least one of the second zones of the pocket-spring core has at least one channel-like depression.

Abstract: A pocketed spring assembly comprises a plurality of parallel strings of springs, each string joined to at least one adjacent string, each string comprising one piece of fabric folded into first and second opposed plies of fabric. Outer pockets are formed along each string by transverse seams joining the first and second plies. One pocketed spring and at least cushion pad is positioned in each outer pocket. The cushion pad may be individually pocketed. An upper end of each transverse seam may be below an upper surface of the string to partially separate adjacent outer pockets within a string.

Abstract: A mattress assembly includes a cover, a spring pack positioned within the cover, and an inner core positioned within the cover. The inner core includes opposite first and second portions. The first portion has a firmness that is different than a firmness of the second portion. The inner core is configured to be moved between a first configuration in which the first portion directly engages the spring pack and a second configuration in which the second portion directly engages the spring pack to alter a firmness of a sleep surface of the mattress. Methods of use are disclosed.

Abstract: Mattresses and improved fabric covers for providing mattresses that have smooth surfaces. Additionally, methods for manufacturing non-quilted mattress covers and for manufacturing mattresses employing non-quilted mattress covers. The systems and methods described herein include mattress panels that can be manufactured separate from the inner core construction, and laid over the inner core to be fastened in place as a sleeping surface for the mattress. Optionally, these mattress panels can include a layer of fire retardant material, that may be added as a layer of material or that may be incorporated into one or more of the layers, such as a filler layer, in the mattress panel.

Abstract: A composite mattress includes a base panel of a cover, a base layer, a pressurizable layer, an intermediate layer, a top layer, and a top panel of the cover. A foundation, or rail, laterally surrounds the pressurizable layer, the intermediate layer, and the top layer. A periphery of the cover laterally surrounds the foundation and, with the top panel and the base panel, encases the other components of the composite mattress. A coiled spring layer may also be included in the composite mattress. The composite mattress may include a separable top and bottom; these elements may be modular, enabling individuals or couples customize a mattress by selecting one or more tops from a plurality of available for use with one or more bases from a plurality of available bases.

Abstract: A pocketed spring assembly comprises a plurality of parallel strings of individually pocketed springs. Each string is joined to at least one adjacent string. Each string has first and second opposed plies of fabric and a plurality of pockets formed along a length of the string by transverse seams joining the plies. At least one spring is positioned in each of the pockets. The water permeable fabric used to make at least some strings comprises warp knit polyester fabric.

Abstract: A posturized comfort layer for a bedding or seating product has different sections of different firmness due to different pocketed mini coil springs within the sections. The springs may be individually pocketed between two sheets of non-woven polypropylene fabric joined with circular or rectangular weld seams. Regardless of the shape of the weld seams, the different firmness of the different sections of the comfort layer may be due to different mini coil springs contained in the pockets. In some embodiments, all pockets may have the same spring and the springs contained in different size weld seams to create pockets of different heights.

Abstract: A posturized comfort layer for a bedding or seating product has different sections of different firmness due to different mini coil springs within the sections. The springs may be individually pocketed between two sheets of non-woven polypropylene fabric joined with circular or rectangular weld seams. Regardless of the shape of the weld seams, the different firmness of the different sections of the comfort layer may be due to different mini coil springs contained in the pockets. All pockets may have the same spring, the springs may be contained in different size weld seams to create pockets of different heights.

Abstract: A pocketed spring assembly comprises a plurality of parallel strings of individually pocketed springs. A dimensionally stabilizing substrate is secured to at least some of the strings on one of the top and bottom surfaces of the strings. A scrim sleet is secured to at least some of the strings on an opposed surface of the strings to maintain the positions of the strings. The dimensionally stabilizing substrate is laterally rigid enough to maintain length and width dimensions of the coil spring assembly. However, the dimensionally stabilizing substrate is flexible enough to allow the pocketed spring assembly to be roll packed for shipping.

Abstract: A mattress cover handle integrated into a mattress cover. The mattress cover is used for covering a mattress on a bed frame. The mattress cover handle include a first horizontal pocket in a first side panel of the mattress cover. Also, a second horizontal pocket in a second side panel can be integrated into the mattress cover. A back side of the first horizontal pocket and a back side of the second horizontal pocket includes webbing or reinforcing tape. The tape can extend along a length of the first and second side panels and sewn next to the sides of the pockets for reinforcing the strength of the pockets. Also, the first and second pockets include seams, which are hemmed around the sides of the each pocket.

Abstract: A pocketed spring comfort layer for a bedding or seating product has pockets characterized by the individual mini coil springs of the comfort layer being pocketed with between at least one cushion assembly and a sheet of polypropylene fabric. Each cushion assembly includes at least one foam layer. A segmented seam joins the cushion assembly and the sheet of polypropylene fabric around each of the mini coil springs of the pocketed spring comfort layer. The method of making the pocketed spring comfort layer includes compressing the mini coil springs and creating pockets with a welding horn and an anvil.

Abstract: A pocketed spring assembly comprises a plurality of parallel strings of springs, each string joined to at least one adjacent string, each string comprising one piece of fabric folded into first and second opposed plies of fabric. Outer pockets are formed along each string by transverse seams joining the first and second plies. One pocketed spring and at least cushion pad is positioned in each outer pocket. The cushion pad may be individually pocketed. An upper end of each transverse seam may be below an upper surface of the string to partially separate adjacent outer pockets within a string.

Abstract: The invention relates to the field of beds or seats. In particular, the invention relates to a flexible element (10) stiffness that is adjustable stiffness along a compression axis (Z), the element including a compression spring (50). In order to enable the stiffness of the stiffness element (10) to be adjusted, it further comprises both a mechanism (150) coupled to the compression spring (50) so as to be actuated by compression of the compression spring (50) along the compression axis (Z) to move in a direction other than the direction of the compression axis (Z), and also an adjustment device for selectively restricting or releasing the movement of the mechanism (150). The invention also provides a unit (200) comprising a plurality of such flexible elements (10), and a method of adjusting the stiffness of the flexible element (10).

Abstract: The present invention is a mattress comprising a first layer of cushion members secured to a layer of coil pockets. The layer of coil pockets comprises first and second coil pockets. Each of the first and second coil pockets comprise a pocket and a coil spring disposed in the pocket. The first layer of cushion members comprises an attachment member and first and second cushion members engaged with said attachment member. The attachment member is engaged with the layer of coil pockets such that the first and second cushion members act directly upon the first and second coil pockets, respectively. The first cushion member is free standing from the second cushion member thereby causing a pumping action to occur upon depression of the first cushion member and circulation of air.

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: The present invention provides a two-stage stiffness type elastomer combined device, including at least one small-stiffness elastic element and a large-stiffness elastic element, wherein the small-stiffness elastic element is arranged in an elastomer pre-compression device and is serially arranged with the large-stiffness elastic element under the action of a pre-compression load F1. The device has combined stiffness being hard at first and then becoming soft and is used as an elastic axle box suspension device of a railway vehicle, effectively solving the contradiction that a linear snaking critical operation speed of the vehicle and curve passing performance of the vehicle cannot be compromised.

Abstract: A modular multi-component mattress system includes a base layer with a coupling channel, a first reversible support pad assembly with a first side rail and a second side rail, a comfort pad layer, and a cover assembly configured to contain the base layer, the first reversible support pad assembly, and the comfort pad layer. In a first configuration, the first side rail detachably and selectively couples within the coupling channel and the second side rail receives the comfort pad layer. In a second configuration, the first side rail receives the comfort pad layer and the second side rail detachably and selectively couples within the coupling channel. The system includes a second reversible support pad assembly. The system includes a topper layer with a cool comfort side and a warm comfort side. The topper layer detachably and selectively couples with the cover assembly.

Abstract: A mattress (10) being asymmetric such that in the same surface (31, 32) of the mattress there are at least two zones (22, 25) or areas of different hardnesses for the different parts (41-44) of the user's (40) body, located such that the first zone (22) or area between the midpoint of the mattress and one end (30a) is softer than the second zone (25) or area between the midpoint of the mattress and the other end (30b). The mattress system has three mattresses (10-10c) of different hardnesses, the zones (21-26) or areas in one side of the mattresses being softer than the corresponding zones or areas in the other side of the mattress.

Abstract: A sleep system includes a sleep surface with a customized profile. The profile of the sleep surface is particularly and specifically designed to maintain a proper sleeping position for an individual. The sleeping surface can include two or more portions that have configurations that ensure the straight alignment of the spine for a person sleeping on the sleep surface. This type of sleep system is customized to each person and, thus, provides a beneficial sleeping position that is individualized and provides the best support for the particular sleeper.

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 pocketed spring assembly comprises a plurality of parallel strings of individually pocketed springs of different heights. Each string is joined to an adjacent string. Each string has first and second opposed plies of fabric and a plurality of pockets formed along a length of the string by transverse seams joining the plies. An upper end of each transverse seam is below the upper surface of the string so as to partially separate adjacent pockets within a string of springs when the spring is relaxed. The strings of springs have ventilation openings to increase airflow.

Abstract: The present invention discloses a sleeping system capable of customization so that at least six different levels of firmness may be achieved per bed. The present invention discloses three layers which may be positioned by the end user in order to achieve the desired firmness. The present invention also includes a method of selling such interchangeable modular bedding. In the method, after selling the bedding, at least one of the three layers may be exchanged in order to achieve yet another alternate firmness level.

Abstract: A portable maternity mat is provided. The portable maternity mat includes at least a first pad and a second pad. Each of the pads has an upper surface and a lower surface. Further, each pad includes a compressible material, such as mattress material. The first pad and the second pad are connected together by a hinged connector. The first pad, the second pad, or a combination of the pads may include a cutout portion through the upper surface. Therefore, a pregnant woman may use the portable maternity mat to lay on their stomach, and may fold the portable maternity mat to move and store the portable maternity mat.

Abstract: The invention describes a coated spring for mattresses that comprises a helical compression spring and a wrapping in the form of a bag containing the spring, wherein the bag containing the spring is injected with a polymeric reaction mixture, which after reacting or curing produces a polymeric foam, preferably of flexible polyurethane up to a desired volume in order to cause the spring to change its flexion or compression properties, as well as the method for its manufacturing and its use in the manufacturing of mattresses of different kinds.

Abstract: A reverse coil head coil and innerspring has a generally cylindrical and helical wire form coil body and opposing coil ends which terminate on opposite sides of a reference plane that passes through the coil body. The reverse coil head coils are interconnected in a matrix to form an innerspring wherein only one terminal end of each coil is located at a perimeter of the innerspring. Variations in the number and pitch of helical turns of the coil body are also disclosed.

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: A mattress includes a mattress body having a top substrate and a bottom substrate separated by a resilient layer having a mattress thickness to resiliently conform to a body of a person. The mattress includes an aperture formed in the top substrate and the resilient layer mattress that is oriented proximate to an upper torso portion of the body of the person. The mattress includes an insert that is shaped to be received in the aperture and has an upwardly open recess to receive an upper portion of the body of the person. An upwardly open recess can be formed directly in the top resilient layer of the mattress body oriented proximate to an upper torso portion of the body of the person.

Abstract: A spring mattress structure comprises a mattress body with a top bed surface and a bottom bed surface developed by a plurality of shaft levers which are regularly arranged and separated by a spacing: each of the shaft levers on which a plurality of springs are installed allows each spring's two bottom ends to be positioned at two adjacent springs; each of the springs has a hollow space corresponding to the spacing developed by two adjacent shaft levers and makes its bottom fixed on a shaft lever with a spring-loaded locating piece; the spring-loaded locating piece comprises a locating part on which a shaft lever is fixed; the locating part has elastic fasteners extending from both sides and used to clamp spring coils of springs so that the springs are stably connected to shaft levers.

Abstract: A mattress includes a spring extending between first and second points to provide a first spring rate in a first direction. A polymer fiber structure is provided between the first and second points and adjoins the spring. The polymer fiber structure includes fibers interlinked with one another to provide the second spring rate in the first direction. An example method of manufacturing a mattress is provided that includes arranging springs to provide a mattress innerspring. A polymer fiber structure is introduced in a first state to the innerspring to provide an assembly. The assembly is further processed and the polymer fiber structure is simultaneously altered from the first state to a second state.

Abstract: Cushions include a plurality of pockets formed from a support material and a deformable member comprising a deformable polymer material disposed in each pocket of the plurality of pockets. The support material may comprise at least one of a fabric and a film. Each of the deformable members may be configured as a column having a column axis. Methods of forming cushions include forming a plurality of deformable members, forming a plurality of pockets from a support material, and disposing each of the deformable members of the plurality of deformable members in each of the pockets of the plurality of pockets. The deformable members may be configured so that each of the deformable members is isolated from the other deformable members by the support material.

Abstract: A mattress assembly may include a foam frame, an inner assembly within the foam frame, the inner assembly including a foam core and a pocketed coil assembly. The pocketed coil assembly can include a plurality of individual pocketed coil springs having a height. Each coil spring may be joined together to a neighboring coil spring such that at least a majority of the height of each coil spring is configured to vertically deflect without deflecting the joined neighboring coil spring.

Abstract: A method for automatically adjusting the hardness of a mattress based on an operator's lying position or an operator's side lying position and a device are disclosed. The device comprises: a base, having hollow platforms that have support legs; a lifting device, below the hollow platforms; a mattress body, disposed on the base and comprising a bed surface, a bed bottom, flexible support units, and gravity sensors, through holes being disposed in the bed bottom and corresponding to the lifting device, the flexible support unit being constructed by a first flexible member female-connected with a second flexible member; and a control device, connected with the lifting device and the gravity sensors, wherein the control device determines that the touching number of the gravity sensors is greater, equal to or less than a preset value and therefore automatically adjusts the hardness of the mattress.

Abstract: A mattress includes a spring extending between first and second points to provide a first spring rate in a first direction. A polymer fiber structure is provided between the first and second points and adjoins the spring. The polymer fiber structure includes fibers interlinked with one another to provide the second spring rate in the first direction. An example method of manufacturing a mattress is provided that includes arranging springs to provide a mattress innerspring. A polymer fiber structure is introduced in a first state to the innerspring to provide an assembly. The assembly is further processed and the polymer fiber structure is simultaneously altered from the first state to a second state.

Abstract: An adjustable bed is provided that has an articulating mattress a number of articulating sections. The bed has an adjustable base with a mechanism to move the articulating mattress into a plurality of positions. The articulating mattress has a number of rigid deck boards. Each articulating section has a corresponding deck board. Adjacent deck boards are hinged together so they can move or rotate with respect to one another. A suspension material, such as pocketed coil springs and/or foam, is disposed above each of said deck boards. A surrounding covering material that encases the deck boards and the suspension material to provide a mattress that can be moved to a number of different positions without any further retaining mechanisms being needed.

Abstract: Mattresses for cots and infant beds include a mattress core having first and second faces. Each face is overlayered by a comfort layer and a cover layer. The mattress core includes a relatively firm core layer and a relatively soft core layer. Suitably, the firm core layer includes an array of helical springs or a foamed polymeric or fibrous material.

Abstract: A bedding or seating product comprising a spring core including upper and lower border wires. Each of the border wires is generally rectangular in cross-section to reduce wire costs without compromising beam strength of the border wire. Each row of springs of the spring core may be made of a single piece of wire. The rows of springs may be arranged in side-by-side rows and columns and be connected with each other by helical lacing wires.

Abstract: A complex spring unit (10) comprises at least a first spring portion (12) and a second spring portion (14), which first and second spring portions are integrally formed, wherein the first spring portion is arranged in use to be placed under compression, and the second spring portion is arranged in use to be placed under tension, during compression of the complex spring unit.

Abstract: Mattress and foundation assemblies generally include a mattress; and a mattress foundation for supporting the mattress, the mattress foundation including a frame configured to elevate the mattress relative to ground; and upper and lower flexible mesh suspension layers spaced apart from one another, each independently supported by a plurality of carriers at discrete points about the surface of the suspension layers, wherein the carriers are pivotably coupled to the frame.

Abstract: A mattress includes a spring extending between first and second points to provide a first spring rate in a first direction. A polymer fiber structure is provided between the first and second points and adjoins the spring. The polymer fiber structure includes fibers interlinked with one another to provide the second spring rate in the first direction. An example method of manufacturing a mattress is provided that includes arranging springs to provide a mattress innerspring. A polymer fiber structure is introduced in a first state to the innerspring to provide an assembly. The assembly is further processed and the polymer fiber structure is simultaneously altered from the first state to a second state.

Abstract: A mattress assembly having a composite encasement surrounding a coil spring unit in which the composite encasement comprises alternating layers of canvas and foam, and in which a side border assembly of quilted material is attached to the exterior walls of the composite encasement by means of multiple, spaced, lines of stitching extending through the alternating layers of canvas and foam to firmly affix the side border assembly to the encasement.

Abstract: A bedding component includes a top portion having a gel foam, a middle portion having a foam layer with at least one gel disc, and a bottom portion having a foam core.

Abstract: A bedding or seating product comprising a spring core including upper and lower border wires. Each of the border wires is generally rectangular in cross-section to reduce wire costs without compromising beam strength of the border wire. Each row of springs of the spring core may be made of a single piece of wire. The rows of springs may be arranged in side-by-side rows and columns and be connected with each other by helical lacing wires.

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 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 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: 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 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: All-foam mattress assemblies with foam engineered cores having thermoplastic and thermoset materials, and related assemblies and methods are disclosed. All-foam mattress assemblies use foam-based materials, such as thermoplastic and thermoset, to provide cushioning and support characteristics for a user in the sleeping area of a mattress during sleep or rest. The all-foam mattress assemblies may include foam comfort layer(s), foam transitional layer(s), and a foam engineered core. The all-foam engineered core may lessen a density of a mattress assembly by comprising thermoset member(s), and engineered geometric thermoplastic material profile(s) adjacent to the thermoset member(s). The engineered geometric thermoplastic material profile(s) may be disposed in a parallel or substantially parallel arrangement.

Abstract: Innersprings with alternating coil spring orientations have columns of interconnected coils in which the axial orientation of the coils alternates one hundred and eighty degrees column to column.