Disclosed is a mattress assembly having a spring or foam core structure and reduced-sized parts. Spaced along the mattress top and bottom border are a plurality of bands having through-openings. Border wire segments extend through the through-openings and are joined end-to-end by releasable connectors to form a continuous border wire providing edge support. Butterfly springs having tube-like bands for receiving the border wire segments prevent sagging. In spring mattresses, the bands, which may be rings or a similar type part, are carried at the top and bottom of the outer springs. In foam mattresses, the bands are formed by a plurality of loops formed in a continuous folded strip fixed by adhesive or other means to the mattress border walls. Two such mattresses may be joined together by interweaving a flexible cord through the bands of adjoining mattresses. The mattress assembly is completed by encasing in an outer cover.

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 mattress has a mattress top, a mattress bottom, and a mattress perimeter. The mattress included the following features. An air chamber has an air chamber perimeter. A coiled spring perimeter includes a first set of coiled springs surrounding the air chamber perimeter. A topper portion has a support layer between the air chamber and the mattress top.

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 of fabric. Outer pockets are formed along each string by transverse seams joining the first and second plies. One pocketed spring and at least cushion pad is positioned in each outer pocket. The cushion pad may be individually pocketed. An upper end of each transverse seam may be below an upper surface of the string to partially separate adjacent outer pockets within a string.

A User Configurable Mattress System and Method for Customizing and Repairing the Same comprising a support cored assembly, a foam assembly, and a covering assembly. The support core assembly is preferably comprised of a high resiliency foam portion, which may include one or more layers of high resiliency foam, and preferably has a thickness between 3 and 12 inches. The foam assembly further is preferably comprised of a first layer of latex foam and a second layer of gel foam. The first layer of latex foam is positioned on top of the second layer of gel foam for users who desire a firmer mattress, the second layer of gel foam is positioned on top of the first layer of latex foam for users who desire a softer mattress. The covering assembly substantially envelopes the support core assembly and the foam assembly, and is selectively removable.

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 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.

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 pocketed spring assembly comprises a plurality of parallel strings of springs, each string joined to at least one adjacent string, each string comprising first and second opposed plies of fabric and a plurality of pockets formed along a length of the string by transverse seams joining the first and second plies. At least one spring is positioned in each pocket. Exterior strings have identical springs in their pockets. Interior strings have two different springs along their length, the outermost springs being firmer than the interior core springs. The pocketed spring assembly has increased firmness or edge support along all four sides due to the different coil springs of the assembly.

A mattress assembly includes a cover having a pocket. A mattress is positioned within the pocket. The mattress includes opposite first and second sides, the first side having a cavity. An insert is positioned within the cavity. Methods of use are disclosed.