Mattresses are packaged by successively rolling two compressed mattresses into a roll in which a rolling wrapper forms a spiral when viewed from an end of the roll. The bottom surface of a first mattress is placed on the wrapper such that the wrapper wraps around a first end of the mattress. The first end is then inserted between the bars of a mechanical roller. The first end is bent over onto the top surface of the mattress, and the mattress is rolled. The bottom surface of a second mattress is placed on the wrapper, and the first mattress is further rolled until successive portions of the bottom surface of the first mattress become adjacent to successive portions of the top surface of the second mattress. The wrapper is cut, and a first location near the cut edge is taped to a second location one revolution earlier on the wrapper.

A sleeping apparatus comprising a textile fiber shell, a plurality of adjustable straps coupled to the textile fiber shell and a plurality of anchors, wherein each anchor is coupled to one of the plurality of adjustable straps, wherein the anchors are configured to attach to one or more structures such that the textile fiber shell forms a flat sleeping surface.

Mattresses including a chassis core including a rigid or semi-rigid base sheet; a plurality of flat springs spaced apart from one another in parallel rows, wherein each one of the plurality of flat springs comprises a first terminal end, a second terminal end, and a flexible arcuate member extending from the first terminal end to the second terminal end, and wherein a center of an arc defined by the arcuate member is fixedly attached to the rigid base sheet; a body support disk disposed on each one of the first and second terminal ends. The body support disk supports the load of an individual. In some embodiments, the body support disk is pivotably connected to each terminal end.

An apparatus is provided which makes a border wire having a rectangular cross-section. The apparatus is adapted to receive a roll of wire having a circular cross-section, straighten the wire and change the cross-section of the wire to rectangular. The reconfigured wire is then accumulated, passed through another straightener, cut to size and then bent into a rectangular configuration. Opposed ends of the piece of wire having a rectangular cross-section are welded together to complete the border wire. The apparatus has an ejector which removes the completed border wire from the apparatus.

A mattress protector and removable cover assembly has a mattress protector for covering a mattress, the mattress protector having an exterior surface having a first zipper portion and a removable cover having a second zipper portion with the second zipper portion for mating with the first zipper portion for the removable cover for attaching to the mattress protector.

An elastic module is provided. The elastic module comprises multiple pre-compressed springs, the multiple pre-compressed springs contact or are adjacent to each other, upper ends of the multiple pre-compressed springs are separated, middle parts of the multiple pre-compressed springs comprise one or more connection members, and middle parts of side surfaces of a front row and a rear row of two adjacent rows of the multiple pre-compressed springs are connected together.

Partially assembled mattress foundations, assembled mattress foundation and methods of manufacture generally include laminating a single piece fabric covering to a foundation frame including a planar support, side fame members, and transverse frame members. During assembly, the laminated fabric covering functions as a hinge such that the operator can fold the various side frame members and transverse frame members about a peripheral edge of the planar support to perpendicular orient the frame members relative to the planar support and form a rectangular shaped fabric covered foundation frame. Corner guards are attached to respective ends of the side frame members and the transverse frame members to form the corners of the foundation frame, wherein the respective ends are at 90 degrees relative to one another, and wherein the corner guard can include an arcuate exterior face.

A pressure sore prevention mattress is provided alternating pressure points on the body of an occupant that is easily transformable between two stable configurations. The four-layer mattress construction has a top foam pad, a webbing layer, a dynamic layer of deformable panels trapezoid-shaped four-bar mechanisms that deform to produce an undulating pattern of peaks, and a base. Panel geometry can determine peak height. The mattress has a spatially hollow geometry that allows natural air convection through the breathable top foam pad to enable drying of moisture as well as the use of forced air convective drying or cooling. The mattress can be transformed from one configuration to the other while the occupant is on the mattress.

An aspect of the present invention relates to a method and system of providing a bed using a plurality of interchangeable adjustable firmness springs to provide localized comfort and support to the user of the bed. The plurality of interchangeable springs may have a plurality of different firmnesses to provide customizable local comfort to a user. The foam springs are color coded based on the firmness associated with the foam spring. The foam springs have markings and/or health devices attached to an end of the foam spring.

In one embodiment, the digital bed system is comprised of an array of support cells. Each support cell is capable of communicating with a controller and increasing and decreasing in firmness in response to commands issued by a controller. The support cells are operatively connected to a communication channel that is also connected to a controller. The controller is capable of receiving data from the support cells and is also capable of issuing commands to each of the support cells. The controller is programmed issue commands to increase or decrease the firmness of individual support cells within the support cells.