A mattress assembly includes a base core layer and an inner core located over the base core layer. The inner core includes coil springs. The mattress assembly also includes a side panel assembly located around a perimeter of the inner core. The side panel assembly includes a spacer fabric located over and transverse to the base core layer. The spacer fabric includes a first knit layer, a second knit layer, and an inner fibrous material located therebetween. Methods of forming the mattress assembly are disclosed.

A hybrid pillow includes a first coil panel and a second coil panel which are joined along peripheral edges to form an inner shell defining a gap therebetween. The first coil panel is formed of a plurality of coil springs, an upper fabric layer, and a lower fabric layer, with the upper fabric layer and the lower fabric layer joined between the plurality of coil springs and along peripheral edges of the first coil panel. The second coil panel is formed of a second plurality of coil springs, a second upper fabric layer, and a second lower fabric layer, with the second upper fabric layer and the second lower fabric layer joined between the plurality of coil springs and along peripheral edges of the second coil panel. A support material disposed in the gap of the inner shell, and one or more additional layers disposed about the inner shell.

Bedding components and processes for forming the bedding components includes an additive manufacturing process to produce a variable elastomeric lattice structure. The variable elastomeric lattice structure includes variations in strut diameter, cell diameter, strut shape, and combinations thereof. The bedding components include mattresses, pillows, coils, mattress toppers or the like and can also be in the form of inserts to provide different feels in different regions.

A mattress assembly includes a base core layer and an inner core located over the base core layer. The inner core includes coil springs. The mattress assembly also includes a side panel assembly located around a perimeter of the inner core. The side panel assembly includes a spacer fabric located over and transverse to the base core layer. The spacer fabric includes a first knit layer, a second knit layer, and an inner fibrous material located therebetween. Methods of forming the mattress assembly are disclosed.

A hollow tubular foam spring having a plurality of radially extending holes extending from an outer surface towards a central hollow core. The tubular foam spring is arranged with wall thickness and diameter to height ratios such that center bulging is achieved under compressive loads. In an embodiment, such as in a mattress, seat, cushion or pillow, springs are arranged in an array whereby some impinge upon one another due to central bulging.

A firmness controlling apparatus for use in a bed arrangement or a seating arrangement is disclosed. The apparatus comprises a rigid frame having two opposed sides, and at least one non-elastic flexible elongate element extending between the two opposed sides. Each end of the non-elastic flexible elongate element is directly or indirectly connected to one of the opposed sides, and at least one of the ends is indirectly connected via an elastic flexible elongate element. A plurality of elongate springs are provided and extend in a flat or curved plane, the ends of each elongate spring being attached to one of the at least one non-elastic flexible elongate elements at two separated connections. A retraction device is arranged to tighten and slack the non-elastic flexible elongate element(s) between the two separated connections, thereby adjusting the distance between the two separated connections of each non-elastic flexible elongate element, and thereby controlling the curvature and height of the elongate springs.

Spring modules for an adjustable sleeping system. At least some of the example embodiments are spring modules comprising: a spring rail, and a plurality of adjustable spring assemblies spaced along the length of the spring rail. Each adjustable spring assembly may comprise: a motor with a stator coupled to the spring rail, a lead screw coupled to the rotor of the motor, and the lead screw extending above an upper surface of the spring rail, a spring plate coupled to the lead screw, and a main spring coupled to the spring plate. Thus, the weight or force carried by each adjustable spring assembly along the spring rail is separately adjustable by a bed controller.

Spring modules for an adjustable sleeping system. At least some of the example embodiments are spring modules comprising: a spring rail, and a plurality of adjustable spring assemblies spaced along the length of the spring rail. Each adjustable spring assembly may comprise: a motor with a stator coupled to the spring rail, a lead screw coupled to the rotor of the motor, and the lead screw extending above an upper surface of the spring rail, a spring plate coupled to the lead screw, and a main spring coupled to the spring plate. Thus, the weight or force carried by each adjustable spring assembly along the spring rail is separately adjustable by a bed controller.

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 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.