Abstract: Mattress assemblies that provide user comfort and increased airflow generally include multilayered foams having open celled structures. Viscoelastic foams can be utilized having intact windows between adjacent cells of less than 50 percent.

Abstract: Mattress assemblies that provide user comfort via independent suspension and increased airflow generally include a first foam layer; a second foam layer configured with an independent response system overlaying the first foam layer, wherein the second foam layer comprises a floor and a plurality of spaced apart support structures extending at about similar lengths from the floor; and a third foam layer overlaying the second foam layer having a planar top surface facing a user resting on the mattress assembly. In some embodiments, the first foam layer further includes a plurality of channels extending from a top planar surface to a bottom planar surface.

Abstract: A mattress constructed with multiple foam layers joined together provides reclining support with pressure redistribution for heavy weight persons, particularly those weighing over 350 pounds. The mattress includes: a core layer having a substantially planar top surface and at least two spaced apart regions in a bottom surface from which foam material has been extracted to leave cavities separated by an interconnected network of foam walls, a top layer of viscoelastic foam with an air permeability above 60 ft3/ft2/min, and a bottom layer of stiffer supporting foam. The open cavities of the core layer are directed away from the body supporting top surface of the mattress and contain one or more gels.

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 system and method according to which a custom mattress is built according to customer-specific parameters. In several exemplary embodiments, the custom mattress includes one or more removable core cartridges and/or one or more removable topper cartridges.

Abstract: In many aspects, the systems and methods described herein include a mattress having a top sleeping layer disposed on top of a support layer. The support layer includes a polyurethane foam having channels aligned with the joints of the articulated sections of the foundation or frame of the adjustable bedding assembly. When the sections articulate about the joints, the channels allow the overlying top layer to conform to the sections while reducing wear and tear therein.

Abstract: A mattress is disclosed that includes a sleeping side, a cushioning layer, an inner support compartment, and a fire-containing compartment disposed between the sleeping side and the inner support compartment and including first and second layers of fire-resistant material. The cushioning layer is disposed between the first and second layers of fire-resistant material.

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 rectangular sleeping pad includes a plurality of projections on one end; a plurality of through holes each correspondingly adjacent to the projection; a plurality of tongues each correspondingly distal the through hole; and a plurality of units each having a first slot at one side of the tongue and a second slot at the other side of the tongue, whereby partially pulling out the tongues will leave a plurality of spaces, and bending one end of the sleeping pad to insert the projections into the spaces, and inserting the tongues through the through holes will temporarily form a pillow.

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 symmetrical pressure relief foam mattress includes an upper foam layer placed on a zoned foam layer. A plurality of cylindrical holes are distributed throughout each of a first, a second and a third lateral region of the zoned foam layer. The first lateral region is less than twelve inches wide and has a middle that is within eighteen inches of the top of the zoned foam layer. The third lateral region is also less than twelve inches wide and has a middle that is within eighteen inches of the bottom of the zoned foam layer. The second lateral region has a middle disposed at the center axis of the zoned foam layer. The middle of both the first and third lateral regions is about fifteen inches from the edge of the mattress regardless of which end the consumer chooses to use as the head of the mattress.

Abstract: Innerspring dampening foam inserts are disclosed in various combinations with mattress innersprings having a plurality of helical form coils interconnected in an array in which the coils are generally aligned in rows and columns, each of the coils having a generally cylindrical coil body formed by helical turns of wire with openings between each of the helical turns of wire, and first and second ends to the coil body also formed by the wire, each of the coil bodies being spaced apart in the array. At least one innerspring insert is inserted into an innerspring in spaces or channels between the spaced apart coils. The innerspring dampening inserts, which are preferably made of foam, may have a generally H-shaped configuration with upper and lower parallel lateral members and a transverse member that extends between and bisects the upper and lower lateral members.

Abstract: A mattress or a mattress pad with one or more gel sections. The gel section may provide improved support and comfort at a localized area of a mattress or a mattress pad.

Abstract: A customizable mattress topper system includes a first mattress topper of viscoelastic foam with a shaped top surface and a second foam mattress topper. The viscoelastic foam topper has a higher density than the second topper. The first mattress topper and second mattress topper are packaged and sold together as a system. The first mattress topper may be placed over the second mattress topper, or vice versa, and in various orientations over a bedding mattress as desired by a consumer to customize the level of cushioning support.

Abstract: An apparatus for providing a sleep support surface that includes a resiliently deformable sleep support having a person-supporting surface and a resiliently deformable layer with a substantially closed elongate opening that accommodates part of a massaging apparatus that has resistive compressive properties of a resiliently deformable layer lacking an elongate opening when the opening is closed. In one embodiment, the sleep support is a mattress having a foam layer with a slit formed therein in which a movable massager that is a massager head of the massaging apparatus is received. One mattress embodiment includes a foam submattress having a lengthwise extending slit extending substantially the length of the mattress and a mattress topper overlying the massager head.

Abstract: A patient support apparatus includes a support surface, which includes at least one fluid bladder and a recess, and a fluid delivery system configured to deliver fluid to the bladder, with at least a portion of the fluid delivery system being located in the recess. The fluid delivery system includes a pump having a fluid output and a fluid input. The apparatus further includes a chamber wall that defines a chamber in fluid communication with the fluid input or output of the pump, with the chamber wall absorbing vibration from the pump when the pump is operated to output fluid at its fluid output.

Abstract: A foam core for a pressure reduction healthcare mattress is disclosed. It includes a top layer made of memory retention foam, a middle layer made of foam and having a convex shape that is higher along a longitudinal center line than along the two sides, and a lower support layer made of foam. The top layer is made of a torso piece and a softer foot/lower leg piece. The middle layer includes a heel pillow that fits into a heel pillow cavity in the foam, the heel pillow including layers of fiber material over a crown shaped foam insert. The lower support layer has a sloped portion in a lower leg section that slopes down toward a heel end of the foam core. Also disclosed is a pressure reduction healthcare mattress that includes the foam core and a cover.

Abstract: A cushion assembly defining a thickness direction comprises at least one covering layer and a core layer. The core layer comprises a first member and a second member. The covering layer spans continuously across both the first and second members in a direction generally transverse to the thickness direction, and the first member is disposed adjacent a forward area of the cushion assembly. The second member is disposed adjacent a back surface of the first member. The second member has a higher resistance to resilient deformation than the first member, and the first member has a higher resistance to resilient deformation than the at least one covering layer.

Abstract: A mattress which comprises a centrer core having a top wall, side walls and end walls, and a layer of memory foam enveloping said central core about said top wall, said side walls and said end walls. A method of manufacturing the above mattress is also disclosed.

Abstract: A versatile support member constructed of a metallic mesh is provided in a bedding product. The support member is placed on top of the mattress core (whether foam or spring coil) before the mattress cover is attached. The support member may be constructed of titanium wire in a woven or welded mesh grid or web configuration, although other metals (such as, but not limited to, vanadium, chromium, platinum, molybdenum, nickel, iron, zinc), alloys thereof, or fiber composites (such as, but not limited to, carbon or graphite) may be used. The support member may be directly attached to the core or may be secured to the upper or lower border rods by hog rings, stitching, lacing, or other conventional means.

Abstract: A mattress system and method according to which a custom mattress is built according to customer-specific parameters. In several exemplary embodiments, the custom mattress includes one or more removable core cartridges and/or one or more removable topper cartridges.

Abstract: A spring element unit for a padding element, especially a mattress, comprises a plurality of spring elements. The spring element consists of an open-cell polyurethane flexible foam material and comprises at least one recess. Such a spring element unit is used in a padding element, especially a mattress, which comprises a base body for receiving the spring element unit. Such a spring element unit prevents a build-up of heat and humidity between the body and the supporting padding element.

Abstract: The invention provides a corrugated mattress and method for making. The mattress comprises an corrugated foam core, a middle cushioning layer and outer cover layer. The corrugated foam core includes an upper substrate, a lower substrate and a fluted middle substrate the flutes fixed to the upper and lower substrates providing three-dimensional support for the user. The middle cushioning layer may comprise a second corrugated foam product, a cotton batting layer, densified polyester or foam including polyurethane, polyester, polypropylene or polylactic acid and the like. The outer cover layer may comprise cotton or laminated foam comprising, polyurethane, polyethylene, polyester, polypropylene, polylactic acid and the like, the laminate comprising a film independently selected from polyurethane, polyethylene, polyester, polypropylene or polylactic acid and the like. In various embodiments the polymers are food grade polymers such that the mattress is non-toxic.

Abstract: The present invention provides a body support assembly comprising a layer having a passage, a pump positioned to create a flow of fluid through the passage, a sensor that detects a parameter and produces a signal, and a controller coupled to the sensor and programmed to control the flow of fluid based on the signal. Preferably, the layer comprises visco-elastic foam. In one embodiment, the parameter corresponds with a firmness of the layer (e.g., a temperature of the layer). A heat exchanger can be used to alter (e.g., heat or cool) a temperature of the fluid. The present invention further provides a method of controlling a firmness of a body support comprising sensing a sensed value of a parameter (e.g., temperature) of the body support, establishing a desired value of the parameter, comparing the sensed parameter to the desired value, and adjusting the parameter.

Abstract: An aspect of the present invention relates to a method and system of receiving information of a user's support facility comfort requirements; using a software application to determine a proper support facility firmness configuration to match the user's requirement; selecting foam springs with the proper user required firmness as determined by the software application; and configuring the selected foam springs within the support facility to match the user's firmness requirements.

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: An aspect of the present invention relates to a method and system of receiving information of a user's support facility comfort requirements; using a software application to determine a proper support facility firmness configuration to match the user's requirement; selecting foam springs with the proper user required firmness as determined by the software application; and configuring the selected foam springs within the support facility to match the user's firmness requirements.

Abstract: A mattress includes a webbing that contains and holds in alignment a plurality of independently configurable zones of foam springs, each one of the plurality of independently configurable zones of foam springs including a plurality of individually replaceable foam springs of varied firmness; and an attachment device that fastens one of the foam springs to the webbing. A method of reconfiguring a foam spring mattress includes opening a webbing in which foam springs are contained; removing a first spring from a location within the webbing; installing a new spring into the location; and closing the webbing, wherein removing the first spring includes disengaging an attachment device that fastens the first spring to the webbing, and wherein installing the new spring includes engaging the attachment device to fasten the new spring to the webbing.

Abstract: The multi-layer multi-material foam mattresses of the present disclosure and related inventions provide novel combinations of multiple layer, multiple material foam layers or stacks which provide unexpected and improved support characteristics and pressure relief and distribution. By combining multiple layers of visco-elastic or latex foam as the top structure of a mattress supported by underlying layers of a laminated urethane foam core, the conformance properties of visco-elastic or latex foam are achieved along with structural support from the underlying core. The multi-layer multi-material foam mattresses of the present disclosure and related inventions include in the various embodiments two or three layers of a first type of foam such as visco-elastic foam or latex foam, in combination with a multi-layer foam support core of a second type of foam such as urethane foam.

Abstract: A mattress including a core foam layer having a first indentation force deflection at twenty five percent compression, a first density and a first thickness. The top outer foam layer has a second indentation force deflection at twenty five percent compression, a second density and a second thickness. The first intermediate foam layer is intermediate and coextensive with the core layer and the top outer layer, and has a third indentation force deflection at twenty five percent compression, a third density and a third intermediate thickness. The first indentation force deflection is greater than the third indentation force deflection and the third indentation force deflection is greater than the second indentation force deflection.

Abstract: A laminated support for pressure-relief comprising multiple foam layers. The combinations of layers can comprise one or more layers of visco-elastic foam, highly resilient polyurethane foam, reticulated filter polyurethane foam, and the like.

Abstract: A method includes selecting an arrangement of foam springs, the arrangement that matches user-selected firmness requirements; attaching foam springs to a foam panel in a removable, replaceable manner; and inserting the foam springs and the foam panel into a containment facility. A mattress includes foam springs; a foam panel to which an arrangement of the foam springs is attached in a removable, replaceable manner; a containment facility within which the foam springs and the foam panel are disposed; and a side rail with indentations within which sides of at least some of the foam springs are disposed. The mattress may also include a fabric webbing, attached to the containment facility, within which some of the foam springs are disposed in a removable, replaceable manner; and an attachment device attaching together at least two of the foam springs.

Abstract: An aspect of the present invention relates to a method and system of receiving information of a user's support facility comfort requirements; using a software application to determine a proper support facility firmness configuration to match the user's requirement; selecting foam springs with the proper user required firmness as determined by the software application; and configuring the selected foam springs within the support facility to match the user's firmness requirements.

Abstract: A laminated support for pressure-relief comprising multiple foam layers. The combinations of layers can comprise one or more layers of visco-elastic foam, highly resilient polyurethane foam, reticulated filter polyurethane foam, and the like.

Abstract: An aspect of the present invention relates to a method and system of receiving information of a user's support facility comfort requirements; using a software application to determine a proper support facility firmness configuration to match the user's requirement; selecting foam springs with the proper user required firmness as determined by the software application; and configuring the selected foam springs within the support facility to match the user's firmness requirements.

Abstract: A spinal-length mattress including a means for providing buoyancy to a human torso and abdomen thereon; attached to the mattress at one end, a pelvic support portion; and attached to the mattress at an opposite end, a head rotation stabilization portion having an air passage opening allowing a person to breathe freely when resting in a face down position thereon. By supporting the pelvis and stabilizing the head to substantially limit motions of the neck, a central cushion (preferably dominated by a “shape memory foam” filling) allows the spinal column to passively distribute all directional stresses—including those deriving from body mass and from muscle tension. Thus relieved of stress, disks between spinal bones begin to return to their respective naturally compliant symmetrical shapes; thereby generally providing a long term benefit in exchange for a quarter hour or a half hour of regular prone-oriented engagement with the mattress.

Abstract: A body support having a number of fluid cells received within respective apertures in one or more layers of foam is described and illustrated. In some embodiments, the fluid cells are in two or more different groups, each of which can be selectively inflated and deflated to increase or decrease pressure against a user's body at different locations across the body support. Each of the fluid cells in each group can be individually surrounded by foam, can be covered by a layer of foam, and can be separated from other fluid cells in the same group by one or more fluid cells from another group. Accordingly, in some embodiments, the cells of one group can be inflated and deflated while or after the cells of another group are deflated and inflated, respectively, to reduce the opportunity for pressure points to generate discomfort of the user.

Abstract: A mattress constructed with multiple foam layers joined together provides reclining support with pressure redistribution for heavy weight persons, particularly those weighing over 350 pounds. The mattress includes: a core layer having a substantially planar top surface and at least two spaced apart regions in a bottom surface from which foam material has been extracted to leave cavities separated by an interconnected network of foam walls, a top layer of viscoelastic foam with an air permeability above 60 ft3/ft2/min, and a bottom layer of stiffer supporting foam. The open cavities of the core layer are directed away from the body supporting top surface of the mattress and contain one or more gels.

Abstract: A mattress (2) which in plan view comprises an inner portion (4) and an outer portion (6), and the mattress (2) being such that the inner portion (4) is of a size for being slept on by at least one person, the outer portion (6) extends at least partially around the inner portion (4), and the inner portion (4) has a lower compression rate than the outer portion (6) whereby the weight of the person on the inner portion (4) is distributed over a greater area than would be the case if the inner portion (4) had the same compression rate as the outer portion (6), and whereby the outer portion (6) constrains the inner portion (4) and controls lateral expansion of the inner portion caused by the weight of the person on the inner portion (4).

Abstract: An aspect of the present invention relates to a method and system of receiving information of a user's support facility comfort requirements; using a software application to determine a proper support facility firmness configuration to match the user's requirement; selecting foam springs with the proper user required firmness as determined by the software application; and configuring the selected foam springs within the support facility to match the user's firmness requirements.

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: A cushioning device with an upper foam layer and a lower positioned foam layer, with the upper foam layer having multiple thickness zones defined by different height projections from one zone to another as to provide a thickness variation pattern, one side of the upper foam layer is less contoured when not yet assembled in the cushioning device and a second side is comprised of the multiple thickness zones such that, upon connection of the multiple thickness zones to the lower positioned foam layer, the height differential along a length of the upper foam layer is transmitted as to form a non-planar, crown configuration in the upper surface of the upper foam layer. A method includes roller contouring different height and shaped projection zones including zones with different ratios of peak height to overall zone height.

Abstract: In one embodiment, a mattress comprises a core and a cushion layer positioned above the core. A fibrous air spacer layer is positioned above the cushion layer, and a layer of visco-elastic foam is positioned above the fibrous layer. This permits the fibrous layer to be sandwiched between the cushion layer and the layer of visco-elastic material.

Abstract: A mattress constructed with multiple foam layers joined together provides reclining support with pressure redistribution for heavy weight persons, particularly those weighing over 350 pounds. The mattress includes: a core layer having a substantially planar top surface and at least two spaced apart regions in a bottom surface from which foam material has been extracted to leave cavities separated by an interconnected network of foam walls, a top layer of viscoelastic foam with an air permeability above 60 ft3/ft2/min, and a bottom layer of stiffer supporting foam. The open cavities of the core layer are directed away from the body supporting top surface of the mattress.

Abstract: A spring element unit for a padding element, especially a mattress, comprises a plurality of spring elements. The spring element consists of an open-cell polyurethane flexible foam material and comprises at least one recess. Such a spring element unit is used in a padding element, especially a mattress, which comprises a base body for receiving the spring element unit. Such a spring element unit prevents a build-up of heat and humidity between the body and the supporting padding element.

Abstract: An aspect of the present invention relates to a method and system of receiving information of a user's support facility comfort requirements; using a software application to determine a proper support facility firmness configuration to match the user's requirement; selecting foam springs with the proper user required firmness as determined by the software application; and configuring the selected foam springs within the support facility to match the user's firmness requirements.

Abstract: A pressure dispersion system includes a pressure dispersion pad and a pressure dispersing mattress system for body support and sleep. The pressure dispersion pad and pressure dispersing mattress systems reduce pressure points from a supported body to less than approximately 32 mm Hg to reduce or eliminate capillary closing and a resultant reduction in pressure concentration and resultant discomfort and repositioning during sleep. Empirical design from human body pressure mapping is used to identify support zones for which components are selected and assembled in the pressure dispersion support systems for pressure dispersion and relief. In a pressure dispersion support system in the form of a mattress, multiple zones are defined by arrangement of different kinds of support materials, including foam tops such as memory foam or moderate to low density polyurethane, and secondary foam layers or foam base of relatively higher density polyurethane and latex.

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: An aspect of the present invention relates to a method and system of receiving information of a user's support facility comfort requirements; using a software application to determine a proper support facility firmness configuration to match the user's requirement; selecting foam springs with the proper user required firmness as determined by the software application; and configuring the selected foam springs within the support facility to match the user's firmness requirements.

Abstract: A suspended matrix support structure has a perimeter frame which supports a flexible matrix formed with intersecting flexible members, the ends of which are supported by the perimeter frame. Edges of the flexible members are held within channels which form a frame about the flexible matrix. In one embodiment, the perimeter frame is constructed of foam with contoured features which support the frame of the flexible matrix. The flexible members of the flexible matrix extend across the expanse within the perimeter frame to provide a flexible support structure which can be used as a mattress, mattress foundation or both in combination.