A method of manufacturing a mattress that comprises forming a mattress inner core; forming a non-quilted mattress cover; and attaching the non-quilted mattress cover to the inner core without sewing. The non-quilted mattress cover may be formed of a laminate including a polymeric non-woven fabric that may be embossed and cut to include a cover top panel and a plurality of cover side panels that are unitary with and extend outward from the cover top panel. The step of attaching the non-quilted mattress cover to the inner core without sewing includes orthogonally orienting the cover side panels relative to the cover top panel and fusing portions of adjoining surfaces of adjacent cover side panels to each other to form a coffin, inserting the mattress inner core into the coffin, folding non-fused portions of the adjoining surface of the adjacent cover side panels over the mattress inner core, and bonding a bottom panel to the non-fused portions of the cover side panels and the mattress inner core.

Body support assembly (1) having a top surface (2) and a spaced away bottom surface (3) defining a cushion volume (4) and defining side walls (5). The air permeability of the top surface (2) is higher than the air permeability of the bottom surface (3). The cushion volume (4) comprises an upper cushion zone (7) and a lower cushion zone (8) and separated by a separation sheet (9). The upper cushion zone (7) and the lower cushion zone (8) comprise of a compressible material (10) which is permeable for air in all directions. The cushion volume (4) further comprises a flow path for air comprising an air inlet (6) in the bottom surface (3), air displacement means (20), a heat exchanger (21), a flow path through the compressible material of the lower cushion zone (8), through openings in the separation sheet (9) and through the compressible material (10) of the upper cushion zone (7) and multiple air outlets as present in the top surface (2).

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 assembly includes a cover, a spring pack positioned within the cover, and an inner core positioned within the cover. The inner core includes opposite first and second portions. The first portion has a firmness that is different than a firmness of the second portion. The inner core is configured to be moved between a first configuration in which the first portion directly engages the spring pack and a second configuration in which the second portion directly engages the spring pack to alter a firmness of a sleep surface of the mattress. Methods of use are disclosed.

An air-conditioned mattress includes a mat device, a cover device, and an air-conditioning device. The mat device includes a first mat configured as a three-dimensional structure made from a plurality of elastic thermoplastic filaments that are randomly tangled with each other. The thermoplastic filaments are fixedly connected at contact portions of the thermoplastic filaments in a way that through holes are formed at non-contact portions of the thermoplastic filaments. The cover device covers the mat device and contacts the top surface of the first mat, and the first mat is more air-permeable than the cover device. The air-conditioning device is disposed inside or outside the mat device and provides heated air flow or cooled air flow into the first mat.

A cushioning structure includes a first layer of a three-dimensional structured mat of extruded entangled filaments, the cushioning structure includes a second layer of a three-dimensional structured mat of extruded entangled filaments, and the cushioning structure includes an intermediate layer between the first layer of the three-dimensional structured mat and the second layer of the three-dimensional structured mat.

The invention is an improved utility bedding product for use on beds or reclining chairs, particularly airplane seats. The inventive product is a multi-layered, lie-flat mattress pad that increases the comfort of passengers by providing a soft resting surface made of materials that permit the flow of air through the mattress pad. In preferred embodiments the mattress pad includes a pocket so the pad may be folded or rolled up and secured in a compact configuration for use as a pillow and for ease of transport.

Mattress assemblies including a hybrid mattress core assembly having a bilayer structure including a fiber layer laminated to a foam layer. Also disclosed are mattress assemblies including a hybrid mattress core assembly having a trilayer structure including a fiber layer sandwiched between first and second foam layers.

A mattress assembly includes a cover, a spring pack positioned within the cover, and an inner core positioned within the cover. The inner core includes opposite first and second portions. The first portion has a firmness that is different than a firmness of the second portion. The inner core is configured to be moved between a first configuration in which the first portion directly engages the spring pack and a second configuration in which the second portion directly engages the spring pack to alter a firmness of a sleep surface of the mattress. Methods of use are disclosed.

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.