A pocketed spring assembly comprises a plurality of parallel strings of springs, each string joined to at least one adjacent string, each string comprising one piece of fabric folded into first and second opposed plies. Outer pockets are formed along each string by transverse seams joining the first and second plies. One pocketed spring, at least cushion pad and at least one buckling member are positioned in each outer pocket. At least one cushion pad, at least one buckling member or any combination thereof may be individually pocketed inside an outer pocket.

A pocket spring unit comprising a plurality of pocket springs each comprising a coil spring and a pocket. Each of the pockets comprise top portion and bottom portions. Each of the pockets are formed from a continuous top piece of fabric attached to a continuous bottom piece of fabric to form a bond having a plane perpendicular to the longitudinal axis of each coil spring. The pocket spring unit further comprises an attachment layer comprising a top portion comprising an inner and outer surface. The pocket spring unit further comprises a plurality of first cushion elements engaged with the outer surface of the top portion of the attachment layer. The inner surface of the top portion of the attachment element is engaged with the top portion of the pockets of the pocket springs such that each of the first cushion elements act only upon one of the pocket springs.

The present invention relates to a pocket spring core (40). The pocket spring core (40) comprises a plurality of pocketed spring elements (41). Each of the plurality of pocketed spring elements (41) is formed of a pocket (42) and at least one coil spring (43) enclosed by the pocket (42). The pocket spring core (40) comprises furthermore a frame element (44) enclosing an arrangement of the plurality of pocketed spring elements (41) along a circumference of the arrangement. The frame element (44) is glued to several pockets (42) of the plurality of pocketed spring elements (41) using a hot melt adhesive, a polyurethane adhesive or an epoxy lime adhesive.

A mattress has an upper foam panel and a lower foam panel. The panels are molded out of a foam material with integrally preferably molded side walls, and there is an assembly of a plurality of spring units placed and secured on or within the lower foam panel. The upper foam panel, when secured above the lower foam panel, covers the assembly of the plurality of spring units and resultantly forms the mattress.

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 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 mattress includes a flex structure having at least one support layer and a plurality of marbles engaged with the at least one support layer and supported by the at least one support layer. The plurality of marbles is arranged in a grid pattern along the at least one support layer.

A mattress includes an alignment layer having a first surface and a second surface arranged opposite to the first surface and defining a plurality of cut-outs extending from the first surface to the second surface and arranged in a plurality of rows in a staggered arrangement. Each cutout of one row partially overlaps with a pair of cutouts arranged in adjacent rows.

A system for manufacturing a string of pocketed coil springs comprising: a coil-forming subsystem that produces two coil springs; a spring transporter subsystem that receives the two coil springs at a first position and conveys the two coil springs to a second position; a spring compressor subsystem that compresses the two coil springs; a fabric-folding subsystem that receives a piece of fabric and folds the fabric to create an open side; a spring inserter subsystem that receives the two compressed coil springs and inserts the two compressed coil springs between top and bottom surfaces of a folded piece of fabric; two welder subsystems that form first and second welds between top and bottom surfaces of the folded piece of fabric, the first welds and the second welds forming a plurality of pockets in the fabric, each of the plurality of pockets comprising a compressed coil spring.

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.