A mattress assembly includes a chassis having top and bottom walls and first and second sidewalls that each extend from the top wall to the bottom wall. Inner surfaces of the walls and the sidewalls define an interior cavity. The top and bottom walls each include a first section that is connected to the first sidewall and a second section that is connected to the second sidewall such that the first sections are pivotable relative to the first sidewall and the second sections are pivotable relative to the second sidewall. The first section of the top wall is pivotable relative to the second section of the top wall and the first section of the bottom wall is pivotable relative to the second section of the bottom wall. A spring assembly is configured to be positioned within the interior cavity.

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 sheet 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.

Mattress assemblies including coil innerspring units, coil innerspring units by themselves, and processes for making the coil innerspring units, wherein the coils within the coil innerspring unit are manufactured with the same geometry, same composition, and from the same gauge wire using different heat treatments to provide the coil innerspring unit with different spring rates.

The invention relates to a method for manufacturing an orthopedic mattress and to an orthopedic mattress. In the method, strategic measuring points of a future user of the mattress are determined. The springing is determined according to the build of the person using the mattress on the basis of a method in which the build dimensions of the mattress user are determined at strategic points.

In systems and methods for adjusting the firmness of a mattress assembly and/or modulating the pressure in a mattress assembly, a mattress assembly includes: a two-dimensional array of bladders; at least one pump that is in fluid communication with the bladders to provide air and/or fluid to the bladders; multiple valves that are interposed between the pump and the bladders to control the flow of air and/or fluid to or from the bladders; a pressure sensor operably connected to one or more of the bladders; and a controller in communication with the pump, the valves, and the pressure sensors. The controller is configured to selectively actuate the pump and one or more of the valves, while receiving feedback from the pressure sensors, in order to adjust the firmness of the mattress assembly and/or modulate the pressure in the mattress assembly.

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 sheet 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.

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 sheet 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.

A pocketed spring assembly comprises parallel strings, each string joined to at least one adjacent string. At least some of the strings have springs of different gauge wire and some of the pockets of the strings having springs of different gauge wire are spliced together. At least some of the strings have springs of different geometries and some of the pockets of the strings having springs of different geometries are spliced together. At least some strings may have end sections with springs different than a middle section therebetween, the springs of the end sections being firmer than the springs of the middle section.

A spring unit containing a spring system used in bed, armchair and sofa like constructions and realizing different hardness and comfort levels in different areas of the constructions and having a soft spring forming a soft comfort area of low hardness of the spring unit, a medium hard spring providing gradual transition between soft comfort areas of the spring unit and hard comfort areas with a spring a having number of convolution different from the soft spring and of the same wire diameter, and a hard spring providing hard comfort area of the spring unit by a spring having number of convolution different from the soft spring and medium hard spring and of the same wire diameter as the medium hard spring and soft spring.

A pocketed spring assembly comprises parallel strings, each string joined to at least one adjacent string. At least some of the strings have springs of different gauge wire and some of the pockets of the strings having springs of different gauge wire are spliced together. At least some of the strings have springs of different geometries and some of the pockets of the strings having springs of different geometries are spliced together. At least some strings may have end sections with springs different than a middle section therebetween, the springs of the end sections being firmer than the springs of the middle section.