Mattress assembly and method

Abstract

A mattress assembly includes a chassis having top and bottom walls and first and second sidewalls that each extend from the top wall to the bottom wall. Inner surfaces of the walls and the sidewalls define an interior cavity. The top and bottom walls each include a first section that is connected to the first sidewall and a second section that is connected to the second sidewall such that the first sections are pivotable relative to the first sidewall and the second sections are pivotable relative to the second sidewall. The first section of the top wall is pivotable relative to the second section of the top wall and the first section of the bottom wall is pivotable relative to the second section of the bottom wall. A spring assembly is configured to be positioned within the interior cavity.

1 - 20 . (canceled) 
     
     
         21 . A bedding system comprising:
 a chassis defining a cavity;   a spring pack positioned in the cavity; and   a topper positioned over the spring pack,   wherein the chassis comprises walls having a folded configuration for chassis packaging and an unfolded configuration that allows for ease of assembly of the spring pack and the topper with the chassis.   
     
     
         22 . The bedding system recited in  claim 21 , wherein the chassis is a unitary element. 
     
     
         23 . The bedding system recited in  claim 21 , wherein the chassis is monolithic. 
     
     
         24 . The bedding system recited in  claim 21 , wherein the walls include opposite first and second end walls and opposite first and second side walls that each extend from the first end wall to the second end wall, the end walls being bonded to the side walls. 
     
     
         25 . The bedding system recited in  claim 21 , wherein:
 the walls include opposite first and second end walls and opposite first and second side walls that each extend from the first end wall to the second end wall; and   interfaces between the end walls and the side walls have a reduced thickness to allow the end walls to pivot relative to the side walls.   
     
     
         26 . The bedding system recited in  claim 21 , wherein:
 the walls include opposite first and second end walls and opposite first and second side walls that each extend from the first end wall to the second end wall; and   the first end wall includes a first section that is coupled to the first side wall and a second section that is coupled to the second side wall, the second section being pivotable relative to the first section to allow the chassis to move between the folded configuration and the unfolded configuration.   
     
     
         27 . The bedding system recited in  claim 26 , wherein the first section is connected to the first side wall by a first mechanical bearing and the second section is coupled to the second side wall by a second mechanical bearing. 
     
     
         28 . The bedding system recited in  claim 26 , wherein the first section is connected to the first side wall by a first hinge and the second section is coupled to the second side wall by a second hinge. 
     
     
         29 . The bedding system recited in  claim 28 , wherein the hinges are living hinges. 
     
     
         30 . The bedding system recited in  claim 26 , wherein the second end wall includes a third section that is coupled to the first side wall and a fourth section that is coupled to the second side wall, the fourth section being pivotable relative to the third section to allow the chassis to move between the folded configuration and the unfolded configuration. 
     
     
         31 . A bedding system comprising:
 a chassis defining a cavity;   a spring pack positioned in the cavity; and   a topper positioned over the spring pack,   wherein the chassis comprises walls having a compacted configuration for chassis packaging and an expanded configuration that allows for ease of assembly of the spring pack and the topper with the chassis.   
     
     
         32 . The bedding system recited in  claim 31 , wherein the chassis is a unitary element. 
     
     
         33 . The bedding system recited in  claim 31 , wherein the chassis is monolithic. 
     
     
         34 . The bedding system recited in  claim 31 , wherein the walls include opposite first and second end walls and opposite first and second side walls that each extend from the first end wall to the second end wall, the end walls being bonded to the side walls. 
     
     
         35 . The bedding system recited in  claim 31 , wherein:
 the walls include opposite first and second end walls and opposite first and second side walls that each extend from the first end wall to the second end wall; and   interfaces between the end walls and the side walls have a reduced thickness to allow the end walls to pivot relative to the side walls.   
     
     
         36 . The bedding system recited in  claim 31 , wherein:
 the walls include opposite first and second end walls and opposite first and second side walls that each extend from the first end wall to the second end wall; and   the first end wall includes a first section that is coupled to the first side wall and a second section that is coupled to the second side wall, the second section being pivotable relative to the first section to allow the chassis to move between the folded configuration and the unfolded configuration.   
     
     
         37 . The bedding system recited in  claim 36 , wherein the first section is connected to the first side wall by a first mechanical bearing and the second section is coupled to the second side wall by a second mechanical bearing. 
     
     
         38 . The bedding system recited in  claim 36 , wherein the first section is connected to the first side wall by a first hinge and the second section is coupled to the second side wall by a second hinge. 
     
     
         39 . The bedding system recited in  claim 38 , wherein the hinges are living hinges. 
     
     
         40 . A bedding system comprising:
 a chassis defining a cavity;   a spring pack positioned in the cavity; and   a topper positioned over the spring pack,   wherein the chassis comprises walls having a folded configuration for chassis packaging and an unfolded configuration that allows for ease of assembly of the spring pack and the topper with the chassis,   wherein the chassis is a unitary element,   wherein the walls include opposite first and second end walls and opposite first and second side walls that each extend from the first end wall to the second end wall;   wherein the first end wall includes a first section that is coupled to the first side wall and a second section that is coupled to the second side wall, the second section being pivotable relative to the first section to allow the chassis to move between the folded configuration and the unfolded configuration; and   wherein the second end wall includes a third section that is coupled to the first side wall and a fourth section that is coupled to the second side wall, the fourth section being pivotable relative to the third section to allow the chassis to move between the folded configuration and the unfolded configuration.