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.

An adjustable mattress is described herein. The adjustable mattress is comprised of one or more adjustable elements. The adjustable elements may, in some examples, be filled with air or other fluid in order to adjust the height and firmness of the adjustable mattress. The adjustable mattress may provide a user with assistance in rolling over or repositioning while using the adjustable mattress.

A bed linen comprises a single, continuous piece of fabric extending substantially completely across lateral dimensions of the bed linen and including elastomeric fibers and non-elastomeric fibers. The single, continuous piece of fabric is configured to stretch to at least 125 percent of an initial length thereof without damage thereto and to substantially return to the initial length thereof after being stretched. A bedding assembly and a method of forming a bedding assembly are also described.

A method for packaging a cushion includes coating a cushioning element with a powder while the cushioning element is in an expanded state and then compressing the cushion to a compressed state. As the cushioning element is compressed, the powder prevents surfaces of the cushioning element (e.g., surfaces of intersecting walls that define hollow buckling columns of a cushioning element formed from an elastomeric polymer extended with a plasticizer, etc.) from adhering to each other. The powder may allow the cushioning element to substantially return to its expanded state substantially immediately following removal of a compressive force from the cushioning element.

A hybrid pillow includes a cushion material defining a recess. A coil panel is positioned within the recess of the cushion material with the coil panel formed of a plurality of coil springs, an upper fabric layer, and a lower fabric layer. The upper fabric layer and the lower fabric layer are joined between the plurality of coil springs and along peripheral edges of the first coil panel. A gel layer is also positioned within the recess of the cushion material and over the coil panel. A method of manufacturing the pillow includes dispensing a liquid gel in a mold, positioning a coil panel in the mold and on top of the liquid gel, dispensing a foam precursor in the mold, and foaming the foam precursor to form a cushion material that is secured to the coil panel.

A gel layer, comprising a first gel lattice having a first geometric shape. The first geometric shape has a first gel lattice height; a first gel lattice width; and a first gel lattice length. The first gel lattice comprises a plurality of first gel segments, wherein the first gel segments define a plurality of first gaps. The first gel lattice has a first firmness.

In some embodiments, a support structures can be formed from a support structure matrix comprising a plurality of layers and a plurality of spring structures embedded within the plurality of layers of the support structure matrix. The plurality of spring structures have a plurality of different durometers. The plurality of spring structures can be configured to deform and return to its original shape after deformation. The orientation and structure of the spring structures can vary depending on a desired durometer and/or function within the support structure.

In some embodiments, a support structures can be formed from a support structure matrix comprising a plurality of spring structures embedded within the support structure matrix. The plurality of spring structures can be formed from the same material or a different material, and can have the same or different durometers. The plurality of spring structures can be configured to deform and return to its original shape after deformation. The orientation and structure of the spring structures can vary depending on a desired durometer and/or function within the support structure.

Mattress assemblies including phase change materials and processes for dissipating retained in the mattress assemblies generally include a spacer layer in proximity to one or more foam layers containing a phase change material; and a pump in fluid communication with the spacer layer to provide a positive or negative air flow into the spacer layer to reduce retained heat in the phase change materials subsequent to a sleep cycle. The process includes operating the pump between sleep cycles to reduce the retained heat.

Mattress assemblies including at least one foam layer at or proximate to a sleeping surface including a plurality of channels or recesses in at least one surface, wherein at least a portion of the channels include an encapsulated bulk phase change material at least partially filling the channel or the recesses.