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 side rail assembly and a mattress assembly including the side rail assembly about at least a portion of a perimeter of the mattress assembly. The side rail assembly includes a laminate structure including one or more foam layers and one or more fiber layers in a stacked arrangement. The fiber layer can be a non-woven layer.

A resilient unit comprises a number of wire coil springs 12, each of which is located within its own discrete pocket 14 formed by first, upper and second, lower layers 14a and 14b of material, preferably of non-woven material. The two layers 14a and 14b have been thermally, or ultrasonically, welded together at points 16 between the adjacent springs to create the pockets. The upper layer of material 14a differs from the lower layer of material 14b in respect of at least one characteristic.

A bed includes a mattress set, an adjustable bedframe to adjust a position or orientation of the mattress, 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. 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.

In described examples, a cushioning unit assembler includes first, second, third, and fourth rows of welding heads, a transport, and a feed module. The welding heads have a welding position and a retracted position. A main axis of the welding heads is oriented in a first dimension while in the welding position. The transport is disposed above the rows of welding heads. The transport has a main axis oriented in a second dimension perpendicular to the first dimension. The feed module includes a pocketed spring intake and a pocketed spring outflow. The transport is mechanically coupled to enable the feed module to move in the second dimension along a scope of movement. An exit aperture of the outflow vertically aligns with welding heads of the first row that are in the welding position, and vertically aligns with welding heads of the second row that are in the welding position.

In described examples, a cushioning unit assembler includes first, second, third, and fourth rows of welding heads, a transport, and a feed module. The welding heads have a welding position and a retracted position. A main axis of the welding heads is oriented in a first dimension while in the welding position. The transport is disposed above the rows of welding heads. The transport has a main axis oriented in a second dimension perpendicular to the first dimension. The feed module includes a pocketed spring intake and a pocketed spring outflow. The transport is mechanically coupled to enable the feed module to move in the second dimension along a scope of movement. An exit aperture of the outflow vertically aligns with welding heads of the first row that are in the welding position, and vertically aligns with welding heads of the second row that are in the welding position.

A mattress includes an outer casing, and an inner core that is surrounded by the outer casing. The mattress has two major faces, two long side faces, and two end faces. The inner core includes a plurality of pocket springs that each have at least one spring within a fabric pocket. Each spring is compressible along a compressive axis, and the pocket springs are arranged within the core such that the compressive axes extend perpendicularly to the two major faces. The pocket springs are arranged into two lateral sets, and a central set. In each lateral set, the fabric pockets of adjacent pocket springs are interconnected in regions adjacent the major faces of the mattress. In the central set, the fabric pockets of adjacent pocket springs are interconnected in regions adjacent the major faces of the mattress. The central set is disposed between the two lateral sets, and extends in a direction parallel to the long side faces of the mattress. The central set is joined directly or indirectly to each of the two lateral sets by first connections that are disposed substantially centrally between the two major faces, such that springs in each lateral set are compressible independently of the springs in the other lateral set.

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 mattress assembly includes a base layer, a coil layer disposed over the base layer, an upper layer disposed over the coil layer, and an elastomeric cushioning element disposed over the upper layer. The coil layer may include a plurality of pocketed coils. Furthermore, the elastomeric cushioning element may have a thickness within a range of about 2.0 inches to about 4.5 inches. Furthermore, the elastomeric cushioning element may form between about 15.0% and about 32.0% of an overall thickness of the mattress assembly. A method of forming a mattress assembly includes disposing a coil layer over a base layer, disposing an upper layer over the coil layer, disposing an elastomeric cushioning element over the upper layer, and disposing an outer covering over at least the upper layer.

A mattress assembly includes a base layer, a coil layer disposed over the base layer, an upper layer disposed over the coil layer, and an elastomeric cushioning element disposed over the upper layer. The coil layer may include a plurality of pocketed coils. Furthermore, the elastomeric cushioning element may have a thickness within a range of about 2.0 inches to about 4.5 inches. Furthermore, the elastomeric cushioning element may form between about 15.0% and about 32.0% of an overall thickness of the mattress assembly. A method of forming a mattress assembly includes disposing a coil layer over a base layer, disposing an upper layer over the coil layer, disposing an elastomeric cushioning element over the upper layer, and disposing an outer covering over at least the upper layer.