An exemplary embodiment provides a method of manufacturing a string of pocketed spring coils comprising: simultaneously making at least two spring coils; simultaneously transporting the at least two spring coils to a compressor: simultaneously compressing the at least two spring coils; simultaneously inserting the at least two compressed spring coils between top and bottom plies of a piece of fabric; welding the top and bottom plies of the fabric along an edge of the folded fabric parallel to the longitudinal axis of the fabric and opposite the folded edge of the fabric; welding the top and bottom plies of the fabric along lines transverse to the longitudinal axis of the fabric between each of the compressed spring coils to create a plurality of pockets, each pocket encompassing a compressed spring coil; and expanding each of the compressed spring coils within each of the plurality of pockets.

A spring assembly is provided that includes a plurality of first strings of springs and a plurality of second strings of springs. Each of the first strings are joined to at least another one of the first strings or one of the second strings. Each of the first strings includes first and second plies of fabric that define a plurality of pockets formed along a length of the first string. The pockets are formed by vertical seams that join the plies. The vertical seams each include an upper slit that extends through a top surface of the first string and a lower slit that extends through a bottom surface of the first string. Each of the pockets have at least one spring positioned therein.

A new approach is proposed that contemplates system and method to support breath monitoring of a person via a plurality of breathing sensors embedded in a mattress the person is resting on. Once activated, each of the breathing sensors is configured to detect breathing activities or body movements caused by the breathing activities of a person lying on the mattress and report the breathing activities detected as electronic signals to a breathing monitor. Upon accepting the signals from the breathing sensors embedded in the mattress, the breathing monitor is configured to identify a breathing pattern based on the breathing activities of the person and detect any abnormal change in the breathing pattern of the person. If such abnormal change is detected, the breathing monitor is configured to generate and provide an alert to a monitoring party/caregiver of the person and/or produce an alarm to wake up the person in sleep.

In order to manufacture an innerspring unit comprising pocketed springs and having an increased stability at its edge regions, in a first step, an innerspring main body comprising a plurality of first strings of pocketed springs is provided. In a subsequent second step, at least one second string of pocketed springs is attached to a lateral surface of the innerspring main body, so that the at least one second string of pocketed springs extends in a longitudinal direction of the innerspring main body. The springs of the at least one second string of pocketed springs have a spring characteristic or a spring geometry different from the springs of the plurality of first strings of the innerspring main body. The at least one second string of pocketed springs forms together with the innerspring main body the innerspring unit.

A spring assembly is provided that includes a plurality of first strings of springs and a plurality of second strings of springs. Each of the first strings are joined to at least another one of the first strings or one of the second strings. Each of the first strings includes first and second plies of fabric that define a plurality of pockets formed along a length of the first string. The pockets are formed by vertical seams that join the plies. The vertical seams each include an upper slit that extends through a top surface of the first string and a lower slit that extends through a bottom surface of the first string. Each of the pockets have at least one spring positioned therein.

A bedding or seating product comprises a pocketed spring assembly comprising a plurality of parallel interior strings of individually pocketed coil springs. The interior strings of springs may extend from head-to-foot or side-to-side of the product. The pocketed spring assembly further comprises at least one perimeter string of springs. Each of the springs of each perimeter string of springs has rectangular convolutions to provide edge support to the product.

A resilient unit suitable for providing comfort, convenience, support or protection is described. The unit typically takes the form of a pad comprising a plurality of pocketed coil springs arranged in an array, each spring being substantially encased in an individual pocket, and the unit being compressible in the axial direction of the springs, wherein each spring comprises a number of coils, and in respect of at least some springs the coils at opposed ends are of different diameter.

A flippable mattress includes a first memory foam layer, a second memory foam layer, a core layer disposed therebetween and a transition layer between each foam layer and the core. The first memory foam layer has a thickness, and the second memory foam layer has a thickness that is greater than the thickness of the first memory foam layer. The first transition layer has an IFD less than that of the second transition layer. The mattress is flippable between a first orientation in which the first memory foam layer is above the core layer and the second memory foam layer, and a second orientation in which the second memory foam layer is above the core layer and the first memory foam layer.

In order to manufacture an innerspring unit comprising pocketed springs and having an increased stability at its edge regions, in a first step, an innerspring main body comprising a plurality of first strings of pocketed springs is provided. In a subsequent second step, at least one second string of pocketed springs is attached to a lateral surface of the innerspring main body, so that the at least one second string of pocketed springs extends in a longitudinal direction of the innerspring main body. The springs of the at least one second string of pocketed springs have a spring characteristic or a spring geometry different from the springs of the plurality of first strings of the innerspring main body. The at least one second string of pocketed springs forms together with the innerspring main body the innerspring unit.

A mattress includes a top face, a bottom face, a pair of opposing sides defining a mattress width there between, a first microcoil support foam layer and a second microcoil support foam layer. The first microcoil support foam layer includes a plurality of first pockets and a plurality of first protrusions, and the second microcoil support foam layer includes a plurality of second pockets and a plurality of second protrusions. A plurality of separate microcoil cells are formed as lines of microcoils having a width of a single microcoil and a length containing sufficient number of microcoils such that the line of microcoils spans the mattress width. Each one of the microcoil cells is disposed between a given second protrusion and first pocket or a given first protrusion and second pocket.