Components of a pocket-sprung-mattress sub-assembly having individual metal springs retained within a matrix of fabric pockets are separated. A rotatable tearing drum 405 is driven by a drive motor 406. Tearing devices 407 are arranged to pull metal springs from a pocket-sprung-mattress sub-assembly during the rotation of the tearing drum 405. A feeding assembly 408 compressors an end portion of the mattress sub-assembly and moves this end portion continually to bring an end of the mattress sub-assembly into contact with the rotating tearing devices 407.

Hybrid coil and air chamber assemblies for cushioning supports generally include pressurized air chambers that are positioned intermediate strings of pocketed coils. In this manner, the coils and air chambers can move independently but can be made to cooperate to provide firmness control, contouring and/or support of a user thereof. Air pressure within the air chambers can be independently adjusted to manipulate firmness and/or contour properties in specific zones defined by the presence and location of the air chambers, e.g., pressure of the air chambers corresponding to the lumbar region can be adjusted to eliminate high pressure points. Still further, the pressure within the air chambers can be automatically adjusted to different applied loads as a function of movement. Also disclose are processes for adjusting a mattress including the hybrid coil and air assemblies.

The disclosure relates to an adjustable bed and foundation thereof, in particular incorporating springs or other support elements into the adjustable bed foundation or frame. The adjustable bed can include one or more foundation spring support sections mounted on or in a mattress support surface of the bed foundation. Spring support sections having different firmness levels in different mattress support sections can provide a varying support level to a user of the adjustable bed foundation combined with a mattress thereon. Spring support sections that are discrete from each other can permit articulation of the corresponding mattress support surface sections without creating bending, elongation, and/or compression stresses which might otherwise cause uneven support from or damage to a continuous spring support element spanning multiple mattress support surface sections.

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.

The present invention is a spring unit for a mattress comprising first and second pocket springs. Each of the first and second pocket springs comprise a coil pocket comprising a pocket and a coil spring disposed in the pocket and a cushion pocket comprising a pocket and a first resilient member disposed in the pocket of the cushion pocket. Each cushion pocket is engaged with and acting only upon the corresponding coil pocket. Substantially the entire side of the pocket of the coil pocket of the first pocket spring is engaged with substantially the entire side of the pocket of the coil pocket of the second pocket spring. Each cushion pocket is free standing and not connected with each other thereby creating a pumping action upon depression of the first pocket spring and/or the second pocket spring that produces circulation of air within the mattress.

A climate controlled bedding system includes at least one coil spring layer; and an air supply fluidly coupled to the one or more fluid conduits. In some embodiments, a filter is disposed within a flow path of a fluid conduit.

A high tension coil spring structure for a bed mattress includes spring bodies and exposed wiring portions which absorb an external load. Diameter-increasing portions (A) are formed on at least one of upper and/or lower end wiring portions (14, 14′) of body wiring portions (12), and provide spaces in which upper and/or lower exposure start wiring portions (16-5, 16-5′) move upward and downward. Rigid support ends (18) are formed on at least one of the body wiring portions (12) and upper and lower exposed wiring portions (16, 16′), and absorb a compressive load. The diameter-increasing portions and the rigid ends of the coil spring structure fundamentally prevent noise caused by friction between the exposed wiring portions and surrounding wiring portions when the exposed wiring portions are compressed and significantly increase the elasticity of the exposed wiring portions.

A customizable mattress includes a chassis defining a cavity. A spring pack is removably positioned within the cavity. A top pad removably covers at least a portion of the spring pack. In some embodiments, kits and methods of use are provided.

A mattress core includes sandwiched layer of coils that includes coils disposed between a first spacer fabric layer and a second spacer fabric layer. The mattress core also includes a viscoelastic foam disposed beneath the sandwiched layer of coils. A top surface of the first spacer fabric layer is disposed at or adjacent to a top surface of the mattress core. The first spacer fabric layer defines or more first air channels and the second spacer fabric layer defines one or more second air channels. The one or more first air channels extend above the coils included in the sandwiched layer of coils and the one or more second air channels extends below coils.

Apparatus for forming a pocketed spring unit, comprising a plurality of strings of pocketed springs and at least one cover sheet, comprises welding tools for welding together the pocketing material and the sheet. One of the welding tools is provided with a cutter for cutting the pocket prior to welding. The tool travels in the direction of Arrow A1, so that the cutter penetrates the pocketing material substantially centrally at the circular proximal end face of the pocket. Once inside the pocket, the tool moves axially through the centre of the spring until it reaches the distal end face of the pocket. Before the end face is reached, the piercing member becomes retracted in the direction of Arrow A2, so that the blade does not pierce the distal end face of the pocket.