Methods and systems for no-glue pocketed spring unit construction. Rows of pocketed springs modules, comprising more than two pocketed springs surrounding a central hole, can be automatically loaded onto an assembler; pocketed spring-surrounded openings can be automatically aligned with welding phalanges; and probe/anvil welding pairs can be inserted into modules in different rows of modules, closed around polymer pocket fabric, and activated to weld rows of modules together without glue; without a user manually loading rows of modules onto the assembler.

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.

A spring core is provided that includes a plurality of coil springs having an upper portion and a lower portion that collectively define an interior cavity. The spring core further includes a continuous upper fabric layer that covers each coil spring and defines a recess in the interior cavity of each coil spring. A cushioning layer is positioned atop the continuous upper fabric layer and extends into the recess in the interior cavity of each coil spring. A mattress assembly is further provided that includes the spring core, an upper body supporting layer, and a lower foundation layer. Methods of producing a spring core are further provided.

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 unit comprising an array of springs 120 located in pockets 180 formed by discrete superposed webs 140 of pocketing material joined together by welds W between the springs, wherein the welds are located at alternately opposite ends of the pocketed springs.

FIG. 1 shows generally a pocketed spring unit at a first stage of manufacture. A row of coil springs 120 (only the end one of which is visible) is introduced by an inserter mechanism 130 into position between axially disposed webs 140a and 140b of pocketing material. The webs 140a and 140b are fed from supply reels (not shown via guide rollers 150. The springs 120 are partly compressed and are pushed between plates 160 towards the webs 140 by the inserter 130 in the direction of Arrow A1.

Once the springs are between the webs 140 a pair of ultrasonic welding tools 170a and 170b joins the webs together at weld locations W between the springs to form individual pockets 180 for the springs. One of the tools is a sonotrode/horn and the other is a base/anvil. Successive rows of springs are encapsulated by welds W that alternate between the axial ends of the springs, so that one is at an upper axial end and the next is at a lower axial end. The webs 140 may also be welded together along their edges (not shown)—i.e. at the ends of the rows—and between adjacent springs in the same row, to fully form the pockets.

A bed according to an embodiment may include a topper, at least one firmness adjuster provided under the topper, and a bedframe configured to have an adjustable position and to support the firmness adjuster. There may be a plurality of firmness adjusters corresponding to a plurality of areas of the bed, and each firmness adjuster may include a plurality of cushions provided in a cushion case and a drive to adjust the firmness of the plurality of cushions. The drive may change a position of a first spring relative to a second spring in each of the cushions to change a perceived firmness by a user lying on top of the topper and the firmness adjusters. A dryer may be provided under the bedframe to keep the cushions and topper dry.

A bed according to an embodiment may include a topper, at least one firmness adjuster provided under the topper, and a bedframe configured to have an adjustable position and to support the firmness adjuster. There may be a plurality of firmness adjusters corresponding to a plurality of areas of the bed, and each firmness adjuster may include a plurality of cushions provided in a cushion case and a drive to adjust the firmness of the plurality of cushions. The drive may change a position of a first spring relative to a second spring in each of the cushions to change a perceived firmness by a user lying on top of the topper and the firmness adjusters. A dryer may be provided under the bedframe to keep the cushions and topper dry.

A bed according to an embodiment may include a topper, at least one firmness adjuster provided under the topper, and a bedframe configured to have an adjustable position and to support the firmness adjuster. There may be a plurality of firmness adjusters corresponding to a plurality of areas of the bed, and each firmness adjuster may include a plurality of cushions provided in a cushion case and a drive to adjust the firmness of the plurality of cushions. The drive may change a position of a first spring relative to a second spring in each of the cushions to change a perceived firmness by a user lying on top of the topper and the firmness adjusters. A dryer may be provided under the bedframe to keep the cushions and topper dry.

A bed includes a mattress set on which a user's body is placed, an adjustable bedframe to adjust a position or orientation of the mattress set for various sitting and sleeping positions, and a dryer to dry the mattress set. The dryer includes a fan, a filter, and a heater to discharge filtered hot air toward the dryer to reduce mildew and mites. A humidity sensing sheet may be provided to sense a humidity level at different regions or areas of the bed, and the dryer may be controlled to supply hot air to regions of the bed having a higher humidity level than a predetermined humidity level or humidity range.

A bed includes a mattress set on which a user's body is placed, an adjustable bedframe to adjust a position or orientation of the mattress set for various sitting and sleeping positions, and a dryer to dry the mattress set. The dryer includes a fan, a filter, and a heater to discharge filtered hot air toward the dryer to reduce mildew and mites. A humidity sensing sheet may be provided to sense a humidity level at different regions or areas of the bed, and the dryer may be controlled to supply hot air to regions of the bed having a higher humidity level than a predetermined humidity level or humidity range.