Abstract: In some embodiments, a support structures can be formed from a support structure matrix comprising a plurality of layers and a plurality of spring structures embedded within the plurality of layers of the support structure matrix. The plurality of spring structures have a plurality of different durometers. The plurality of spring structures can be configured to deform and return to its original shape after deformation. The orientation and structure of the spring structures can vary depending on a desired durometer and/or function within the support structure.

Abstract: An apparatus for bonding and combining a pocket spring bed mesh and method, and a pocket spring bed mesh. The apparatus includes a rack, a platform arranged on the rack for driving the pocket spring bed mesh to move reciprocally, a rotating mechanism used for driving the pocket spring bed mesh to rotate, and a combining mechanism used for combining pocket spring strings to form the pocket spring bed mesh. The combining mechanism bonds and combines pocket spring strings to form an unshaped pocket spring bed mesh which is driven by the platform to move to the position of rotating mechanism to be rotated for adjusting the orientation, then the pocket spring bed mesh is moved by the platform to the combining mechanism, and the combining mechanism bonds and combines the side parts of the unshaped pocket spring bed mesh using a pocket spring string of a smaller diameter.

Abstract: Compressible mattress assemblies for bed in a box applications generally include a first foam layer and a second foam layer, wherein the first foam layer has a thickness less than the second foam layer and has a property and/or a foam material that is different from the second foam layer. In other embodiments, the compressible mattress assemblies consist of a pocketed microcoil array intermediate the first and second polymeric foam layers.

Abstract: A side rail assembly and a mattress assembly including the side rail assembly about at least a portion of a perimeter of the mattress assembly. The side rail assembly includes a laminate structure including one or more foam layers and one or more fiber layers in a stacked arrangement. The fiber layer can be a non-woven layer.

Abstract: A supporting module comprises a sensing spring, an outer spring and a sensor, wherein the sensing spring is slightly higher than the outer spring, the sensing spring is sleeved inside the outer spring, and the bottom of the sensing spring is connected to the sensor. An automatically adjustable bed, comprising the supporting module.

Abstract: Present embodiments provide various open coil spring assemblies which perform like an encased spring assembly. The embodiments have elastic lacings or connections which connect springs to springs or springs to lacings. Various spring embodiments are provided as well as various arrangements for the elastic lacings. All of these features improve compliance and stability while reducing motion transfer.

Abstract: A seat component for a vehicle seat having at least one air outlet unit configured to be connected to an air supply. In order to be able to adapt a ventilation function of the vehicle seat individually to a contact area between the vehicle seat and a person sitting thereon, the air outlet unit has at least one flexible air guide funnel and at least one diaphragm valve which is arranged within the at least one flexible air guide funnel and which is connected to the at least one flexible air guide funnel in such a way that the diaphragm valve closes the air guide funnel when the air guide funnel is not deformed, and at least partially opens the air guide funnel when the air guide funnel is deformed.

Abstract: A mattress mount that has a paddle, a riser and an air conduit clamp. The riser spaces the paddle apart from the air conduit clamp at different elevations. A compressible, resilient cushion is secured to a flat surface of the paddle. The paddle with cushion is positioned underneath a mattress to compress the cushion. The paddle extends from the riser to terminate at ta free end. The air conduit claim extends outwardly from the riser to terminate at free ends. The paddle and the air conduit clamp extend at different elevations and in opposite directions from the riser to terminate at their respective free ends.

Abstract: A mattress having a foam core is provided. The foam core may include a channel along two or more sides of the foam core. Spring coils in the channel(s) provide increased localized support proximal the outer edge of the mattress. The spring coils may be conventional spring coils or individually pocketed spring coils. In certain alternatives, the spring coils may be replaced by foam different than the foam core; such difference may include foams having a higher indentation force deflection (IFD) rating. The mattress may have a foam core that is provided with an undercut filled with a foam insert where a higher IFD foam is provided in the undercut.

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 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: 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 mattress (22) having a core structure (8) wherein side walls (15) are compressed inward and held in place using a preferably non-woven strip of fabric (21) or similar non-elastic or non-stretchable material that is wrapped around the side walls.

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 (22) having a foam core (8) completely extends to the perimeter edges of the mattress wherein side walls (15) of the foam core are compressed inward and held in place using a preferably non-woven strip of fabric (21) or similar non-elastic or non-stretchable material that is wrapped around the side walls of the foam core. A method of wrapping the foam core allows corners (5) of the foam core to be formed under the inward pressure of the non-woven fabric, thereby creating a strong perimeter for the mattress that prevents outward pressure against the sidewalls created by the downward pressure of an individual lying on the mattress from flattening of the mattress by providing more upward pushback against the individual. An optional layer of micro-coil springs (2a) may be located within the foam core to provide more buoyancy and springiness in the mattress.

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 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 multi-needle quilting machine (20) is provided with a tape or ribbon guide (30) that is operated by a method by which a narrow strip (32) is fed against a facing layer (11a) of a wide multi-layered material (24) as it is fed into the quilting machine. In the quilting machine (20), series of chain stitches are sewn, at least one of which joins the tape (32) and layers of the multi-layered material (24) together with the same thread in a quilting process, thereby applying the tape (32) to the quilted product in a single quilting operation without the need for a post-quilting tape application step. The tape may form a decorative strip or have unsewn sections that serve as handles for a mattress when the quilted product is formed into a mattress cover.

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 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: Encasement assemblies, systems, and related methods employing interlocking support components to provide at least a portion of an encasement for bedding or seating are disclosed. The assembly may include a base having flip-up support member(s). The base may include elongated channel(s) disposed therein having a first geometry and a portion of the elongated channel(s) may also be disposed in the flip-up support member(s). The assembly may also include elongated support member(s) each having a first side and a second side. The first side may contain a rail and the second side may contain a second rail. Each rail and second rail may be interlocked with the elongated channel(s), such that the elongated support member(s) are attached to the base and provide at least a portion of the encasement.

Abstract: The modular mattress designed to be easily assembled. The mattress assembly includes a double-border wire unit having a central cavity. The cavity is adapted to receive a matrix of coil spring units therein. The coil spring matrix is removably attached to the double-border wire unit. Foam rubber forms are inserted into the wire unit to form the perimeter of the mattress without using glue or similar fastening means.

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: Stepped-edge and side-support members, systems, assemblies, and related methods for an innerspring assembly or other core are disclosed. In one embodiment, an innerspring assembly or core is provided having an interior area of a first height surrounded by one or more exterior, perimeter area(s) of shorter height(s) to provide a stepped-edge innerspring assembly or core. At least a portion of side-support members are placed onto at least a portion of the top surface of the perimeter area to provide edge-support for the innerspring assembly or core. In this manner, a greater portion of the side-support members can be disposed in the sleeping area of the innerspring assembly or core since the underlying perimeter area provides spring support to the side-support members. Further, this support can assist in retention and/or recovery of the shape of the side-support members to further prevent or reduce compression set of the side-support members.

Abstract: A mattress includes a first spring unit having a first degree of firmness, a second spring unit having a second degree of firmness different from the first degree of firmness, and a transition zone that is disposed between the first and second spring units. A foam perimeter surrounds the first and second spring units and the transition zone. The transition zone has a first row of springs adjacent to the first spring unit and has a degree of firmness between the first and second degrees of firmness that is closer to the first degree of firmness than the second degree of firmness. The transition zone also has a second row of springs adjacent to the second spring unit and has a degree of firmness between the first and second degrees of firmness that is closer to the second degree of firmness than the first degree of firmness.

Abstract: A bedding or seating product comprising a spring core including at least one border wire and a plurality of coil springs. Each of the border wires is generally rectangular in cross-section to reduce wire costs without compromising beam strength of the border wire. Each of the coil springs may be made of a single piece of wire having a central spiral portion defining a central spring axis and terminating at opposed ends with upper and lower end turns. The coil springs may be arranged in side-by-side rows and columns and be connected with each other at the upper and lower end turns by helical lacing wires.

Abstract: A bedding foundation has a wire core which may be nestably stacked with numerous other such assemblies for transportation, thereby avoiding the need to compress and tie multiple assemblies for shipping. The wire core which includes an upper wire grid made of four distinct border wires and support wires extending between two opposing border wires. Each support wire has flattened valleys below the plane of the upper wire grid, each flattened valley being adapted to be secured to a wooden base frame. The wire cores, wooden bases and corner guards may be shipped separately.

Abstract: By providing a plurality of preformed components which are quickly and easily affixed in engagement with each other, a final construction is realized which peripherally surrounds any desired mattress configuration in cooperating association therewith. In this way, a new foam plastic product is achieved which is capable of being quickly and easily mounted to mattress constructions peripherally surrounding the mattress and providing an enhanced side support system. In this way, any desired mattress size or configuration is capable of being peripherally surrounded with a foam support assembly for enhancing the mattress construction and configuration. Furthermore, by employing the present invention, a rapid, convenient, and virtually labor free assembly is realized.

Abstract: A mattress system has a cover, a crib, and a fluid bladder system. The crib surrounds the perimeter of the fluid bladder system and the cover overlies the top surface of the crib and fluid bladder system. The fluid bladder systems provide at least one conventional bladder therapy to a patient positioned on the mattress system. The fluid bladder system interconnects to the crib to not form a hammock effect so the crib functions as a restraint. The fluid bladder is also designed to bottom out to form an exterior cavity. A second cushion is inserted into the exterior cavity and positioned so the crib continues to function as a restraint. The second cushion provides a therapy to the patient that is different from the fluid bladder system.

Abstract: There is disclosed a mattress comprising a first border member configured to define an upper periphery of the mattress and a second border member configured to define a lower periphery of the mattress. At least two spring assemblies are positioned within the first and second border members so as to extend between the first and second border members. Each spring assembly comprises an array of coil springs and each spring assembly is positioned such that the coil springs of one spring assembly are not directly connected with coil springs of any other spring assembly.

Abstract: Disclosed is a mattress including a plurality of springs arranged in rows to provide an innerspring, and at least one polymer fiber rail including polymer fibers interlinked with one another. The at least one polymer fiber rail has a face adjoining one of the rows of springs. The at least one polymer fiber rail can be tuned to provide desired characteristics, and, together with the springs, the rail provides a comprehensive mattress system.

Abstract: By forming a plurality of separate, spaced, expansion zones in preselected areas of a foamed plastic product having a desired size and shape, a new foam plastic product is achieved which is capable of being expanded or extended in at least one direction during its use in order to accommodate dimensional changes or requirements. By forming the expansion zones in a precisely desired pattern which extends over a substantial portion of the foam plastic product, the resulting product is capable of being expanded, extended, or adjusted in at least one of its dimensions. In this way, the resulting product is quickly and easily expanded or extended in one direction to fit any desired application surface with ease and simplicity.

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: Densified fiber structures are incorporated into mattress constructions and bedding Applications. In one embodiment, a mattress innerspring is combined with one or more densified fiber structures which fit with the innerspring and with other components of the mattress. An innerspring perimeter support made of densified fiber may encase the outer perimeter of the innerspring and provide structural side walls to the mattress. In another embodiment and application, the inner cavity of one or more coils of a mattress innerspring may be substantially filled with densified fiber. In yet another embodiment, the general space between the coils of the innerspring may be filled with densified fiber.

Abstract: An internal corner structures for mattress foundations that sit at each corner between the frame and the grid. The rigid member contains a base, body and grid support deck. The base member sits atop the foundation frame and contains two flanges that overlap the frame and guide the positioning of the internal corner structure relative to the frame. The body structure supports the grid deck and has a rounded exterior profile to provide a rounded smooth contour to the mattress foundation corners, and has a plurality of square shaped openings that extend in both a vertical and horizontal direction. The grid support deck sits atop the body structure and provides support to the mattress foundation grid, and has engagement clips that engage and position the grid and an edge guard that functions to disperse a load and protect the engagement clips from impact.

Abstract: A stiffening system for the perimeter edges of a foam core mattress comprising a coil spring (or other spring-based) structure disposed along one or more perimeter edges (e.g., one or both side edges, the foot, the head, or a combinations thereof including the foot and both side edges) of a mattress having a foam sleeping area. The perimeter spring structure is rectangular or square in cross-section and provides sufficient stiffness for comfortable seating on the edges of the mattress and is joined to the foam core by planar fabric elements that span the joint between them and are attached to both. The sleep area provides the softness and other salutary effects of a foam sleeping surface while the stiffer spring perimeter element provides the rigidity need for comfortable seating and wear resistance.

Abstract: A mattress including a housing having a panel forming a base and a border connected to the panel, wherein the panel and border define a receptacle having a first end and a second end. The mattress further includes a spring assembly positioned on the panel and within the receptacle, wherein the spring assembly comprises a plurality of first and second coils arranged in rows extending continuously from the first end to the second end of the receptacle, wherein the first coils are different in size from the second coils; wherein groups of one or more of the first coils and groups of one or more of the second coils define at least three zones of firmness between the first end and the second end of the receptacle, wherein each of the first and second coils includes a first end and a second end; and wherein the first ends of the first and second coils are disposed adjacent the housing panel and lie in a first plane parallel to the housing panel.

Abstract: A zoned mattress including at least a head firmness zone, a leg firmness zone between the head and leg firmness zones overlaid by a knit top fabric knit from threads of at least two different colors to define three different firmness indicating areas corresponding to the three firmness zones of the mattress. At least one of the firmness indicating areas is defined by threads differing in color as compared to the color of the threads defining at least one of the two remaining firmness indicating areas.

Abstract: Expandable edge-support members, assemblies, and related methods are disclosed. The expandable edge-support members can be used to provide edge support, including side support and corner support. The expandable edge-support members are suitable for bedding and seating applications as examples. The expandable edge-support members are expandable in length. Thus, the expandable edge-support members can be expanded in length as needed to be utilized to provide edge support for an innerspring having variations in perimeter lengths and different types of innersprings having variations in perimeter lengths. Further, the edge-support members may include a plurality of lateral members, which may be configured to be disposed between adjacent perimeter coils of an innerspring to support attachment to the innerspring.

Abstract: An innerspring assembly includes a plurality of first springs arranged side-by-side in axis-parallel relationship and wound in the form of a helix. Several first springs which are arranged behind one another in a row define a spring strand. An edge reinforcement is formed by second springs placed on at least two opposite borders of the innerspring assembly, with each second spring being connected with two first springs of an adjacent spring strand.

Abstract: A mattress embodying a foam encasement surrounding individually wrapped coils and lacking a barrier separating upholstery layers from the coil assembly. Border material is affixed to sidewalls forming the foam encasement and the upholstery layer is tacked to a base of the foam encasement.

Abstract: An infant mattress fits safely in a crib without any gap between the mattress and the walls or bars of the crib. A ring of memory foam surrounds the supporting foam layers of the mattress and forms a snug fit with the vertical bars of the crib regardless of whether the dimensions of the particular crib or mattress vary from their standard sizes. The memory foam ring intentionally renders the infant mattress somewhat larger than the inner dimensions of the crib. The ring compresses when the mattress is placed in a crib in which opposing side bars are separated by a distance that is smaller than the mattress width. The ring is formed by pouring foam into a rectangular mold around the supporting foam layers. Where the mattress includes pocket coils on the supporting foam layers, the ring of memory foam conforms to the outer row of pocket coils.

Abstract: A mattress includes a chamber defined by upper and lower panels and a peripheral border all constructed from synthetic polymeric/copolymeric plastic material and housing therein a spring unit. The spring unit includes a plurality of springs having upper ends connected to a peripheral border rod. The spring unit is devoid of a peripheral border rod at lower ends of the springs. Upper edges of the spring unit can be deformably gripped by the upper panel, the peripheral border and/or both to prevent “swimming pool” effect.

Abstract: Stepped-edge and side-support members, systems, assemblies, and related methods for an innerspring assembly or other core are disclosed. In one embodiment, an innerspring assembly or core is provided having an interior area of a first height surrounded by one or more exterior, perimeter area(s) of shorter height(s) to provide a stepped-edge innerspring assembly or core. At least a portion of side-support members are placed onto at least a portion of the top surface of the perimeter area to provide edge-support for the innerspring assembly or core. In this manner, a greater portion of the side-support members can be disposed in the sleeping area of the innerspring assembly or core since the underlying perimeter area provides spring support to the side-support members. Further, this support can assist in retention and/or recovery of the shape of the side-support members to further prevent or reduce compression set of the side-support members.

Abstract: An edge support for reinforcing an edge of a spring core is provided. The edge support includes a plurality of engaging members that are movable between flat and folded positions. In the flat position, an engaging member is generally aligned with the rest of the edge support. In the folded position, the engaging member extends laterally from the rest of the edge support. With the engaging members in the flat position, the edge support has a relatively thin thickness allowing the edge support to be rolled which may be beneficial for the shipping and handling of the edge support. During the assembling of the mattress, the engaging members may be moved to the folded position such that engaging members extend inwardly into the spring core between the spring coils of the spring core.

Abstract: Disclosed herein is a bed mattress and a method of manufacturing the same, in which a permeable reinforcing member is provided at an upper portion and a lower portion of a spring assembly which is one of frame constituents of the bed mattress, and a foaming material is disposed on the permeable reinforcing member so as to be foamed, so that the spring assembly and the foaming material are integrally formed while the foaming material is expanded through fine holes and/or foam expansion holes of the permeable reinforcing member.

Abstract: A dual spring support structure for mattresses or other reflexive support structures employs a foam spring in combination with an innerspring or foam core, to provide a multi-mode and multi-structural support surface with a multiple, constant, or complimentary spring rate and support characteristics. Foam springs have geometric cross-sectional configurations with mechanical spring properties which work in concert with the spring properties of foam. Foam springs are used in one embodiment about the perimeter of a wire form innerspring or about the perimeter of a foam core. The foam springs may have a spring rate that is complimentary to, greater than or less than the spring rate of the innerspring or core. Foam springs of different configurations and spring rates can be combined with different types of cores, or used alone to provide a spring or cushioning structure.

Abstract: Embodiments disclosed in the detailed description include a unitary or monolithic composite or hybrid cushioning structure(s) and profile(s) comprised of a cellular thermoplastic foam and a thermoset material. The thermoset material may also be provided as cellular foam as well. In one embodiment disclosed herein, the unitary composite cushioning structure is formed from a cellular thermoplastic foam and a thermoset material. The cellular thermoplastic foam provides support characteristics to the unitary composite cushioning structure. The thermoset material provides a resilient structure with cushioning characteristics to the cushioning structure. A stratum is disposed between at least a portion of the cellular thermoplastic foam and at least a portion of the thermoset material to secure the at least a portion of the thermoset material to the at least a portion of the cellular thermoplastic foam to provide a unitary composite cushioning structure.

Abstract: A mattress foundation with a perimeter structure has a frame, springs mounted upon the frame, and a grid supported by the springs, and perimeter structure at a perimeter of the frame which extends from the frame to the grid, forming an exterior wall which extends from the frame to a border wire of the grid. When the perimeter structure is made of structural and reflexive material such as closed-cell foam, it co-acts with the grid and springs and provides additional support to the perimeter region of the grid and foundation. The exterior wall of the perimeter structure forms a solid surface over which padding or upholstery is placed.