Adjustable bed assembly with magnetic attachment and method of manufacture

Abstract

To provide an adjustable bed assembly using a magnetic attachment system for securing a mattress to an adjustable base.SOLUTION: The magnetic attachment system 40 includes a magnetic member for securing to a lower surface of the mattress and at least one magnet 70 configured to secure to an upper surface of the adjustable base. The magnetic member may have a magnetic bar or may have a flexible bar with one or more metal plates disposed at predetermined locations on the flexible bar. A cover may surround the mattress, the cover being adjacent a lower surface of the mattress and including a pocket for receiving the magnetic member and defining one or more windows such that when the magnetic member is received in the pocket, the one or more metal plates are exposed via the windows. The adjustable bed assembly includes a mattress and an adjustable base operatively connected with a magnetic attachment system.SELECTED DRAWING: Figure 6

Description

[Technical Field]

[0001] [Related Applications] This application claims priority to U.S. Provisional Patent Application No. 63 / 227,006, filed July 29, 2021, the entire disclosure of which is incorporated herein by reference.

[0002] The present invention relates to adjustable bed assemblies, and more particularly, certain embodiments of the present invention relate to adjustable bed assemblies that use a magnetic attachment system to secure a mattress to an adjustable base. [Background technology]

[0003] Bed assemblies using adjustable bases are becoming increasingly popular as an alternative to traditional bed assemblies. Unlike traditional bed assemblies that use rigid box springs or other similar bases, bed assemblies using adjustable bases can be easily adjusted by articulating the base to an ergonomically desirable position. In other words, by articulating the adjustable base, a user can easily change the position of a mattress residing on the adjustable base, thereby quickly adjusting the mattress position to specific preferences and, at least in part, individualizing the level of sleep comfort.

[0004] Despite the easily adjustable nature of such bed assemblies, the use of adjustable bases often makes it difficult to manipulate the mattress that rests on top of the base. More specifically, in bed assemblies that use adjustable bases, the adjustable bases often include a rigidly secured retainer bar at the foot of the base, which holds the mattress firmly in place on the base and prevents it from sliding off the base when articulated. However, in using such a rigid retainer bar, the retainer bar also acts to prevent the mattress from being easily manipulated, such as may be necessary to rotate the mattress or change the sheets covering the mattress. Furthermore, in addition to the undesirable aesthetics of using a large metal retainer bar at the foot of the bed, bed assemblies that use such retainer bars in combination with adjustable bases frequently exhibit undesirable mattress bridging, where the mattress separates from the underlying base when articulated. Such bed assemblies are also frequently subject to the mattress itself tearing and extending beyond the retainer bar. Therefore, an improved adjustable bed assembly that can secure a mattress to an adjustable base without the undesirable aesthetic and other problems encountered with the use of retainer bars would be highly desirable and beneficial. Summary of the Invention

[0005] The present invention includes an adjustable bed assembly and a magnetic attachment system. In particular, certain embodiments of the present invention include an adjustable bed assembly that uses a magnetic attachment system to secure a mattress to an adjustable base.

[0006] In one exemplary embodiment of the invention, an adjustable bed assembly includes a mattress having a lower surface, an adjustable base having an upper surface, and one or more magnetic attachment systems, each including a magnetic member for securing to the lower surface of the mattress and at least one magnet configured to be secured to the upper surface of the adjustable base.

[0007] In some exemplary embodiments, the one or more magnetic attachment systems include a first magnetic attachment system positioned adjacent to a top or middle portion of the mattress and adjustable base, and a second magnetic attachment system positioned adjacent to a foot portion of the mattress and adjustable base.

[0008] In some exemplary embodiments, the one or more magnetic attachment systems have at least two sets of magnets.

[0009] In some exemplary embodiments, the at least one magnet defines a central opening, and the at least one magnet is secured to the adjustable base using a fastener disposed through the central opening.

[0010] In some exemplary embodiments, a plastic shell is disposed around at least one magnet, or a metal ring is disposed around at least one magnet, or both a plastic shell and a metal ring are disposed around at least one magnet.

[0011] In some exemplary embodiments, the mattress includes a pocket adjacent the lower surface of the mattress for receiving the magnetic member, hi some particular embodiments, a cover surrounds the mattress, the cover including a pocket adjacent the lower surface of the mattress for receiving the magnetic member.

[0012] In some exemplary embodiments, the magnet member includes a magnet bar. In other exemplary embodiments, the magnet member includes a flexible bar and one or more metal plates disposed at predetermined locations on the flexible bar. In some specific embodiments that also include a pocket for receiving the magnet member, the pocket defines one or more windows that respectively correspond to the predetermined locations of the one or more metal plates, such that when the magnet member is received in the pocket, the one or more metal plates are exposed through the windows.

[0013] In some exemplary embodiments, at least one magnet housing configured to be secured to the upper surface of the adjustable base is included, each magnet housing including a central channel configured to receive a magnet member and one or more magnets disposed in the central channel of the at least one magnet housing.

[0014] In some exemplary embodiments, the mattress is a flexible foam mattress. In some specific embodiments, the flexible foam is a viscoelastic foam.

[0015] Further features and advantages of the present invention will become apparent to those skilled in the art after consideration of the description, drawings, and non-limiting examples herein. [Brief explanation of the drawings]

[0016] [Figure 1] 1 is a perspective view of a mattress included in an adjustable bed assembly made in accordance with the present invention, showing two magnetic members in the form of magnetic bars positioned in pockets in the cover on the underside of the mattress.

[0017] [Figure 2] FIG. 1 is a perspective view of an adjustable base included in an adjustable bed assembly made in accordance with the present invention, showing a plurality of magnet housings secured to the upper surface of the adjustable base, the magnet housings each having one or more magnets in a central channel of the magnet housing.

[0018] [Figure 3] 2 is a top view of a magnetic attachment system made in accordance with the present invention, showing one of the magnet bars of FIG. 1 in isolation engaging three of the magnet housings of FIG. 2;

[0019] [Figure 4] FIG. 2 is a detailed view of the portion identified in FIG. 1, with the magnetic bar partially removed from its pocket on the underside cover of the mattress.

[0020] [Figure 5] 2 is a perspective view of one magnet housing of FIG. 1 shown in isolation, the magnet housing including two magnets disposed in a central channel of the magnet housing.

[0021] [Figure 6] FIG. 4 is a partially exploded perspective view of the magnetic attachment system shown in FIG. 3, showing the connection between one magnet bar and one magnet housing.

[0022] [Figure 7] FIG. 10 is a partially exploded perspective view of another magnetic attachment system made in accordance with the present invention.

[0023] [Figure 8] FIG. 8 is a perspective view of the magnetic attachment system of FIG. 7 in an assembled configuration.

[0024] [Figure 9] FIG. 10 is a partially exploded perspective view of another magnetic attachment system made in accordance with the present invention.

[0025] [Figure 10] FIG. 10 is a perspective view of a portion of the magnetic attachment system of FIG. 9 in an assembled configuration.

[0026] [Figure 11]10 is a top view of an adjustable base included in an adjustable bed assembly made in accordance with the present invention, showing two of the magnetic attachment systems of FIG. 9 implemented;

[0027] [Figure 12] FIG. 10 is a perspective view of another adjustable base included in an adjustable bed assembly made in accordance with the present invention, wherein a plurality of magnets are secured directly to the upper surface of the adjustable base without an intervening magnet housing.

[0028] [Figure 13] FIG. 1 is a perspective view of a fabric panel used to make a mattress cover having pockets for receiving magnetic members.

[0029] [Figure 14] FIG. 14 is a perspective view of the fabric panel of FIG. 13 beginning to fold to form a loop.

[0030] [Figure 15] FIG. 15 is a perspective view of the fabric panel of FIG. 14, but further folded to complete the loop that will be sewn to form the pocket.

[0031] [Figure 16] FIG. 16 is a perspective view of the fabric panel of FIG. 15, but with the pocket flattened to allow for insertion of the magnetic member.

[0032] [Figure 17] 17 is a perspective view of another mattress having a cover including the fabric panel of FIG. 16 adjacent the underside of the mattress. DETAILED DESCRIPTION OF THE INVENTION

[0033] The present invention includes an adjustable bed assembly and a magnetic attachment system. In particular, certain embodiments of the present invention include an adjustable bed assembly that uses a magnetic attachment system to secure a mattress to an adjustable base.

[0034] Referring first generally to FIGS. 1-6, in one exemplary embodiment of the present invention, an adjustable base assembly is provided that includes a mattress 20 (see FIG. 1) having a lower surface 22 and an adjustable base 30 (see FIG. 2) having an upper surface 32, such that when the mattress 20 is placed on the adjustable base 30, the lower surface 22 of the mattress 20 rests on and contacts the upper surface 32 of the adjustable base 30. The mattress 20 is generally constructed of a flexible foam, which may include, but is not limited to, latex foam, reticulated or non-reticulated viscoelastic foam (sometimes referred to as memory foam or low-resilience foam), reticulated or non-reticulated non-viscoelastic foam, high-resilience polyurethane foam, expanded polymer foam (e.g., expanded ethylene vinyl acetate, polypropylene, polystyrene, or polyethylene), and the like. In the exemplary embodiment shown in FIGS. 1-6, for example, the mattress is constructed of a viscoelastic foam that has low resilience but sufficient firmness and density so that pressure is evenly distributed throughout the mattress 20.

[0035] Regardless of the particular type of material (e.g., foam) used in the exemplary mattress, when the mattress 20 is placed on the adjustable base 30 and the adjustable base 30 is articulated, the weight of the mattress 20 and / or the weight of a user reclining on the mattress 20 has the potential to cause the mattress 20 to slide downward across the upper surface 32 of the adjustable base 30. To prevent such movement of the mattress 20 relative to the adjustable base 30, the adjustable bed assembly of the present invention, as shown in connection with FIGS. 3 and 6, includes a magnetic attachment system 40 comprised of a magnetic member 50 secured to the lower surface 22 of the mattress 20. As used herein, the term "magnet" refers to a material that is attracted to a magnetic field. While the exemplary magnetic member 50 is comprised of a ferromagnetic material, other materials are contemplated for use in the magnetic members of the present invention, including, in some embodiments, permanent magnets or electromagnets. The magnetic attachment system 40 further includes a magnet housing 60 secured to the upper surface 32 of the adjustable base 30 and one or more magnets 70 disposed in the magnet housing 60. As described further below, the exemplary one or more magnets 70 are permanent magnets, although in some other embodiments, it is contemplated that the magnets secured to the adjustable base are electromagnets. Regardless of the particular type of magnetic member and magnets utilized, when the mattress 20 is placed on the upper surface 32 of the adjustable base 30, the magnetic members 50 are positioned adjacent to the magnets 70 in their respective magnetic housings 60 disposed on the lower surface 22 of the mattress 20, thereby securing the mattress 20 to the adjustable base 30 and preventing it from sliding relative to the adjustable base 30. Thus, the shape and configuration of the magnetic members and magnets are each selected to provide sufficient attractive force to secure the mattress 20 to the adjustable base 30 and prevent it from sliding.

[0036] 1-2, in the exemplary adjustable bed assembly, to effectively secure a mattress 20 to the adjustable base 30, the adjustable base assembly includes a first magnetic attachment system 40 disposed between the upper and middle portions 12, 14 of the adjustable base assembly, and a second magnetic attachment system 40 disposed adjacent to the foot portion 16 of the adjustable base assembly. Further, in this exemplary embodiment, each magnetic attachment system 40 is comprised of one magnetic member 50 and three magnetic housings 60, each housing containing one or two magnets 70. Of course, it is contemplated that additional or alternative magnetic attachment assemblies including a different number of magnetic members or different numbers of magnetic housings and / or magnets may be readily incorporated into the exemplary adjustable bed assembly without departing from the spirit and scope of the present invention. For example, in certain embodiments, two or more magnetic members and / or three or more magnetic housings and associated magnets may be included in the exemplary adjustable bed assembly to secure a larger mattress (e.g., king size) to the adjustable base. Alternatively, in other embodiments, fewer than two magnetic members and / or fewer than three magnetic housings and associated magnets may be included in an exemplary adjustable bed assembly to secure a smaller mattress (e.g., twin size) to the adjustable base.

[0037] 1 and 4, the magnetic member 50 in this exemplary embodiment is in the form of an elongated solid metal bar and is secured to the underside 22 of the mattress 20 by sliding the magnetic member 50 into a pocket 24 on a cover 21 that surrounds the mattress 20. The exemplary cover 21 includes a zipper 23 that allows the cover 21 to be removed from the mattress 20 so that the magnetic attachment system 40 can be utilized without requiring any modifications to the mattress 20. However, in other embodiments, it is contemplated that the cover is part of the mattress itself, such that the pocket 24 is formed directly on the underside of the mattress. Although not explicitly shown, in some other embodiments, the magnetic member can be affixed directly to the mattress itself without the use of a pocket. In such embodiments, a cover or other fabric layer may still be provided over the magnetic member itself.

[0038] Regardless of the particular configuration of the cover 21, in this embodiment, the pocket 24 completely surrounds and encases the cover 21 to secure the magnetic member 40 to the cover 21. However, as described below, it is contemplated that in other embodiments, the pocket may surround and secure only a certain portion of the magnetic member to the cover while leaving other portions of the magnetic member exposed, thereby allowing for more direct contact between the magnetic member and the magnetic housing and associated magnet of the exemplary magnetic attachment system. For example, the pocket may be in the form of a split sleeve having separate and distinct portions that surround and secure the magnetic member, or, as described below with reference to Figures 13-17, the pocket may define a window that exposes a portion of the magnetic member.

[0039] With respect to the magnet housing, and now referring to Figures 2, 3, 5 and 6, the magnet housing 60 is generally constructed of a sufficiently rigid plastic material (e.g., polypropylene) or other non-magnetic material and is secured directly to the upper surface 32 of the adjustable base 30 using a number of fasteners 73 (e.g., screws) that extend through raised portions on either side of the magnet housing 60, perhaps best seen in Figures 5-6. In this manner, the magnet housing 60 defines a central channel 62 that extends the entire length of the magnet housing 60, the central channel 62 being wide enough to receive and secure the magnet member 50 within the central channel 62 and relative to the magnet 70.

[0040] With regard to the magnets 70 themselves, as perhaps best shown in FIG. 6 , each magnet 70 defines a central opening 72 that allows the magnet 70 to be secured to the magnet housing 60 and underlying adjustable base 30 by placing appropriate fasteners 73 therethrough. To reduce non-specific interactions between magnetic objects and the magnets 70, a plastic shell 74 and a metal ring 76 are further disposed around the magnets 70, and the magnets 70 are held in place by fastening them to the magnet housing 60 and underlying adjustable base 30 with the fasteners 73. In this regard, in the exemplary magnetic attachment system 40, the magnets 70 are neodymium magnets, and up to two magnets 70 are included in each magnet housing 60 to enable the magnetic attachment system 40 to have sufficient strength to secure the mattress 20 to the adjustable base 30. It is further contemplated that different arrangements, including different types and numbers of magnets, may be readily included in the exemplary magnetic housing and magnetic attachment assembly, as needed for a particular application.

[0041] 7-8, in another embodiment of the present invention, a magnetic attachment system 140 is provided that includes a magnet housing 160 that includes a central channel 162, similar to the magnetic attachment system 40 shown in FIGS. 1-6. The magnetic attachment system 140 further includes a magnet 170 that is secured to the magnet housing 160 using a fastener 173 inserted through a central opening 172 in the magnet 170, and that is surrounded by a plastic shell 174 and a metal ring 176. However, unlike the magnetic attachment system 40 shown in FIGS. 1-7, the magnetic member 150 included in the magnetic attachment system 140 is not an elongated solid metal bar. Rather, the magnetic member 150 is an elongated metal bar having one or more lightening holes 152 that serve to reduce the weight of the magnetic member 150.

[0042] 9-11, in a further embodiment of the present invention, another magnetic attachment system 240 is provided that includes a magnet housing 260 having a central channel 262 and a magnet 270, similar to that shown in FIGS. 1-8, with the magnet 270 secured to the magnet housing 260 using fasteners 73 inserted through the central opening 272 of the magnet 270, and surrounded by a plastic shell 274 and a metal ring 276. However, in the magnetic attachment system 240, the magnetic member 250 is not simply comprised of a single piece of metal. Rather, the magnetic member 250 is comprised of multiple materials, and more specifically, a bar 252 made of a flexible plastic material (e.g., polyethylene) and one or more metal plates 254 positioned in predetermined positions along the length of the flexible bar 252. 11, upon assembly of the exemplary adjustable bed assembly, the metal plate 254 is thus positioned on the flexible bar 252 such that the metal plate 254 can align with the underlying magnet housing 260 and magnets 270 connected to the adjustable base 230. Furthermore, by constructing the flexible bar 252 from a flexible plastic material, the flexible bar 252 thus not only reduces the weight of the magnetic attachment system 240, but also serves to incorporate overall flexibility into the system, allowing the mattress of the exemplary adjustable bed assembly to be more easily released from the underlying adjustable base. While the embodiment shown in FIGS. 9-11 utilizes fasteners (e.g., screws) to secure the metal plate 254 to the flexible bar 252, any number of securement means are contemplated, including adhesives, welding, molding, overmolding, etc.

[0043] While each of the magnetic attachment systems 40, 140, 240 described above includes a magnet housing 60, 160, 260 in which the magnets 70, 170, 270 are disposed, according to some other embodiments, and referring now to FIG. 12 , the magnets 370 are mounted directly to the top surface 332 of the adjustable base 330. In this exemplary embodiment, the magnets 370 are arranged in two groups, with three sets of magnets 370 aligned to engage with one magnet member (not shown) and two sets of magnets 370 aligned to engage with the other magnet member (not shown). Of course, the particular number and arrangement of the magnets 370 are not limited. Regardless of the number or arrangement, the exemplary magnets 370 are configured similarly to the magnets 70, 170, 270 described above, with a central opening that allows the magnets 370 to be secured to the adjustable base 330, and further with a plastic shell and metal ring disposed around the magnets 370.

[0044] 17, in another exemplary embodiment of the present invention, similar to mattress 20 shown in FIG. 1, a mattress 420 is provided that includes a cover 421 having pockets 424 on a lower surface 422 of the mattress 420 that are used to secure magnetic members (not shown) to the cover 421. Each pocket 424 defines an access hole 428 at each end of the pocket 424, allowing a magnetic member, such as any of the magnetic members 50, 150, or 250 described above, to be inserted into the pocket 424. Furthermore, as described above, the exemplary pocket 424 surrounds and secures certain portions of the magnetic members to the cover, while leaving other portions of the magnetic members exposed, thereby allowing for more direct contact between the magnetic members and associated magnets of the exemplary magnetic attachment system. To this end, each pocket 424 shown in FIG. 17 also includes a plurality of windows 426 that expose portions of the magnetic members inserted into the pocket 424. In some embodiments, the locations of the windows 426 correspond to predetermined locations of metal plates that are positioned at predetermined locations along the length of the flexible bar such that one or more metal plates are exposed through the windows when the magnetic members are received in the pockets.

[0045] According to some exemplary methods of the present invention, and with reference to the exemplary mattress 20 shown in FIG. 1 , pockets 24 for receiving magnetic members 50 are formed by sewing the pockets 24 to the cover 21 adjacent the underside 22 of the mattress 20. According to this method, as perhaps best shown in FIG. 4 , the resulting pockets 24 have open ends that allow the magnetic members 50 to slide into the pockets 24. However, in other embodiments, and with reference now to FIGS. 13-17 , the pockets are formed by folding a single fabric panel to form loops, then sewing the panel along these folds and closing the loops to form the pockets. Advantageously, these “fold-and-sew” pockets provide a pivot axis, allowing the mattress to better conform to the adjustable base when the adjustable base is articulated. Furthermore, allowing the pockets to pivot about the stitching lines reduces wear on the pockets over the life of the mattress.

[0046] In one exemplary method of forming such a "fold and sew" pocket, and with particular reference to FIG. 13 , a fabric panel 480 is first provided that includes four sets of cuts 482a-482d along the edges of the fabric panel 480. These cuts 482a-482d serve to align corresponding stitching lines 484a-484d that extend across the fabric panel 480, as described further below. It should be understood that the stitching lines 484a-484d are not necessarily visible, but rather are imaginary lines that extend across the transverse axis of the fabric panel 480 between the corresponding cuts 482a-482d. The fabric panel 480 also defines a plurality of large cutouts 486 and a plurality of small cutouts 488 that are bordered on two sides of the stitching lines 484a-484d.

[0047] 14, fabric panel 480 is folded such that two pairs of upper stitching lines 484a, 484b (see FIG. 13) begin to form a first loop, and similarly, two pairs of lower stitching lines 484c, 484d (see FIG. 13) begin to form a second loop. As mentioned above, in some embodiments, stitching lines 484a-484d are imaginary and not actually visible. Thus, cuts 482a-482d are intended to provide the visual and physical markers necessary to ensure the loops are of the proper size and position.

[0048] 15, folding of fabric panel 480 continues until the first loop is completed (i.e., the first set of cuts 482a is adjacent to the second set of cuts 482b) and the fabric panel 480 is sewn along the now-adjoining stitching lines 484a, 484b (see FIG. 13) to form the first pocket 424. Similarly, the second loop is completed (i.e., the third set of cuts 482c is adjacent to the fourth set of cuts 482d) and the fabric panel 480 is sewn along the now-adjoining stitching lines 484c, 484d (see FIG. 13) to form the second pocket 424.

[0049] Referring now to FIG. 16, the pocket 424 is flattened to allow for subsequent insertion of the magnetic member, as further described below.

[0050] 17 , the fabric panel 480 is incorporated into a cover 421 that, together with the fabric panel 480, surrounds the mattress 420 adjacent to the underside 422 of the mattress 420. Specifically, the edges of the pocket 424 are closed, for example, by sewing or binding an additional piece of fabric around the periphery of the fabric panel 480 during the process of forming the cover 421. Thus, the multiple small cutouts 488 in the fabric panel 480 form access holes 428 that allow magnetic members (e.g., the magnetic members 50, 150, 250 described above) to be inserted into the pocket 424. The larger cutouts 486 similarly form windows 426 that expose portions of the magnetic members inserted into the pocket 424.

[0051] Those skilled in the art will recognize that additional embodiments are possible without departing from the teachings of this invention or the scope of the claims that follow. This detailed description, and particularly the specific details of the exemplary embodiments disclosed herein, are given primarily for clarity of understanding and no unnecessary limitations should be understood therefrom; modifications will become apparent to those skilled in the art upon reading this disclosure and may be made without departing from the spirit or scope of the claimed invention.

Claims

1. a mattress having a lower surface; an adjustable base having an upper surface; one or more magnetic attachment systems; 1. An adjustable bed assembly comprising: a magnet member for fastening to the underside of the mattress; at least one magnet configured to be secured to the upper surface of the adjustable base; An adjustable bed assembly, including:

2. the one or more magnetic attachment systems a first magnetic attachment system positioned adjacent to the mattress and an upper or central portion of the adjustable base; a second magnetic attachment system positioned adjacent to the mattress and a foot portion of the adjustable base; 10. The adjustable bed assembly of claim 1, comprising:

3. the one or more magnetic attachment systems having at least two sets of magnets; 10. The adjustable bed assembly of claim 1.

4. the at least one magnet defines a central opening, and the at least one magnet is secured to the adjustable base using a fastener disposed through the central opening.

10. The adjustable bed assembly of claim 1.

5. further comprising a plastic shell disposed around the at least one magnet, or further comprising a metal ring disposed around the at least one magnet, or further comprising both a plastic shell and a metal ring disposed around the at least one magnet; 10. The adjustable bed assembly of claim 1.

6. the mattress including a pocket adjacent the lower surface of the mattress for receiving the magnet member; 10. The adjustable bed assembly of claim 1.

7. The adjustable bed assembly further comprises a cover surrounding the mattress, the cover adjacent the lower surface of the mattress and including a pocket for receiving the magnetic member.

10. The adjustable bed assembly of claim 1.

8. The magnet member includes a magnet bar.

10. The adjustable bed assembly of claim 1.

9. The magnet member has a flexible bar and includes one or more metal plates disposed at predetermined positions on the flexible bar.

10. The adjustable bed assembly of claim 1.

10. the magnet member has a flexible bar and includes one or more metal plates disposed at predetermined positions on the flexible bar; the pocket defines one or more windows respectively corresponding to the predetermined positions of the one or more metal plates, such that when the magnet member is received in the pocket, the one or more metal plates are exposed through the windows; 7. The adjustable bed assembly of claim 6.

11. The adjustable bed assembly further comprises at least one magnet housing configured to be secured to the upper surface of the adjustable base, each magnet housing including a central channel configured to receive the magnet member and one or more magnets disposed in the central channel of the at least one magnet housing.

10. The adjustable bed assembly of claim 1.

12. The mattress is a flexible foam mattress.

10. The adjustable bed assembly of claim 1.

13. The flexible foam is a viscoelastic foam.

11. The adjustable bed assembly of claim 10.

14. a magnetic member for fixing to the underside of the mattress; two or more sets of magnets configured to be secured to the upper surface of the adjustable base; A magnetic attachment system comprising:

15. Further comprising a plastic shell disposed around each magnet, or further comprising a metal ring disposed around each magnet, or further comprising both a plastic shell and a metal ring disposed around each magnet; 15. The magnetic attachment system of claim 14.

16. The magnet member includes a magnet bar.

15. The magnetic attachment system of claim 14.

17. The magnet member has a flexible bar and includes one or more metal plates disposed at predetermined positions on the flexible bar.

15. The magnetic attachment system of claim 14.

18. The magnetic attachment system further comprises a cover surrounding the mattress, the cover being adjacent to the lower surface of the mattress and including a pocket for receiving the magnetic member, the pocket defining one or more windows respectively corresponding to predetermined positions of the one or more metal plates, such that when the magnetic member is received in the pocket, the one or more metal plates are exposed through the windows.

18. The magnetic attachment system of claim 17.

19. providing a fabric panel having a longitudinal axis and a transverse axis; folding and sewing the fabric panel to form a pocket extending along the transverse axis of the fabric panel; forming a cover incorporating the fabric panel, wherein the cover is configured to enclose the mattress together with the fabric panel adjacent the underside of the mattress; inserting a magnetic member into the pocket; providing an adjustable base having an upper surface and at least one magnet secured to the upper surface of the adjustable base, whereby when the mattress with the cover is placed on the adjustable base, the magnetic member is positioned relative to the at least one magnet to secure the mattress to the adjustable base; 1. A method of manufacturing an adjustable bed assembly comprising:

20. forming a plurality of cutouts in the fabric panel to expose portions of the magnetic members to be inserted into the pockets; 20. The method of claim 19.

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