DREAMWELL, LTD.

Adjustable mattress assemblies and processes including an adjustable mattress foundation dimensioned to support a mattress configured to accommodate two supine users during use thereof includes a foundation frame including a first sub-foundation configured with at least one motorized actuator to effect inclination or declination of the mattress support surface and an abutting second sub-foundation free of a motorized actuator. The second foundation is mechanically coupled to the first foundation such that articulation of the first sub-foundation results in a similar articulation in the second foundation. The first and second foundations have similar length, height and width dimensions, which collectively approximates the size of the oversized mattress configured to accommodate two supine users, e.g., king size, queen size, California king size, or the like.

A composite layer for use in a bedding product such as a mattress and a method of manufacture are disclosed. The composite layer generally includes an extruded three dimensional fibrous layer and a foam material, e.g., polyurethane, latex or the like, disposed within the fibrous layer and occupying at least a portion of the free volume in the layer. Also disclosed are processes for manufacturing a foam-fiber composite.

Mattress assemblies include a hybrid posture support system that provide an end user with improved posture support during use, among other advantages. The hybrid posture support system includes a top foam layer including first and second foam portions that are spaced apart and generally correspond to a head/shoulder region and a foot region, respectively, a pocketed microcoil array underlying the top foam layer that is intermediate the first and second foam portions; and an underlying foam layer. The hybrid posture support system can be used in any mattress assembly including mattresses having a coil spring innercore or a foam innercore.

Temperature management bedding systems for mattresses and quilt panels generally include a trilayer of active components including a phase change material applied to a top surface of a flexible substrate thereof, a fire retardant layer underlying the flexible substrate including hydrophilic rayon fibers treated with ammonium polyphosphate; and a vertically oriented fiber batting layer underlying the first retardant layer including an elastomeric binder. The temperature management bedding systems provide heat control and mass transfer of moisture from the bedding surface.

Mattress assemblies including at least one encapsulated panel including a layer of fibers and/or foam saturated with a heat absorbing material. The layer is completely encapsulated with a liquid impermeable and flexible material. The heat absorbing material is not microencapsulated.

Flame retardant panels generally include an adaptive cover layer and underlying batting layer. The cover layer includes a moisture vapor permeable synthetic fibrous layer, and a liquid impermeable but moisture vapor permeable thermoplastic layer disposed on an outer face of the cover layer, wherein the liquid impermeable but moisture vapor permeable thermoplastic layer is in an amount of about 2 to 15% by weight based on a total weight of the synthetic fibrous layer and the thermoplastic layer. The underlying batting layer can have a top surface and a bottom surface, the layer comprising a plurality of substantially vertically oriented flame retardant treated fibers extending from the top surface to the bottom surface; and a binder material.

Active comfort controlled bedding systems include a variable firmness control and/or variable climate control.

Mattress assemblies including static and adjustable mattress foundations generally include a foundation frame including side frame members and transverse frame members attached at respective ends by a corner bracket at each of the respective ends to define a generally rectangular shape. An adjustable support leg coupled to each one of the corner brackets for automatically elevating the foundation frame relative to ground. The adjustable support leg can include an outer tubular member fastened to an interior facing portion of the corner bracket including an end cap, wherein the end cap includes an aperture. A motorized linear actuator can be coupled to the outer tubular member, which can include a motor and an extendible portion coupled to the motor. The extendible portion is configured to selectively retract from and extend through the end cap to change the elevation of the foundation frame relative to ground.

Mattress assemblies including static and adjustable mattress foundations generally include a foundation frame including side frame members and transverse frame members attached at respective ends by a corner bracket at each of the respective ends to define a generally rectangular shape. An adjustable support leg coupled to each one of the corner brackets for automatically elevating the foundation frame relative to ground. The adjustable support leg can include an outer tubular member fastened to an interior facing portion of the corner bracket including an end cap, wherein the end cap includes an aperture. A motorized linear actuator can be coupled to the outer tubular member, which can include a motor and an extendible portion coupled to the motor. The extendible portion is configured to selectively retract from and extend through the end cap to change the elevation of the foundation frame relative to ground.

A sleep concierge system is provided and includes a bedding assembly configured to assume multiple configurations with multiple settings and a computing device. The computing device is configured to communicate with the bedding assembly and to control the bedding assembly to assume a selected configuration with selected settings in in accordance with user inputs in response to a predefined event.