Abstract: A mattress topper for fitting to a mattress may include a lower layer, a side layer configured to extend down along a side of the mattress, and an upper layer overlaying the lower layer and at least partially disposed between the lower layer and the side layer. The mattress topper may also include a seam including threads and extending along peripheral edges of the lower layer and the upper layer and extending through the lower layer, upper layer, and side layer, the lower layer and side layer bearing the threads of the seam. An air table may include a top panel including a plurality of vents extending through the top panel. A method of making a mattress topper with an air table may include lifting the mattress topper with the air table while performing sewing procedures on the mattress topper.

Abstract: A mattress topper for fitting to a mattress may include a lower layer, a side layer configured to extend down along a side of the mattress, and an upper layer overlaying the lower layer and at least partially disposed between the lower layer and the side layer. The mattress topper may also include a seam including threads and extending along peripheral edges of the lower layer and the upper layer and extending through the lower layer, upper layer, and side layer, the lower layer and side layer bearing the threads of the seam. An air table may include a top panel including a plurality of vents extending through the top panel. A method of making a mattress topper with an air table may include lifting the mattress topper with the air table while performing sewing procedures on the mattress topper.

Abstract: Elastomeric cushion members may include a plurality of interconnected buckling walls including an elastomeric material. The interconnected buckling walls may together define a plurality of columns. A perforated skin may extend between at least some of the plurality of interconnected buckling walls of at least some of the plurality of columns. Methods of making elastomeric cushion members may involve interconnecting a plurality of buckling walls including an elastomeric material. The interconnected buckling walls may together define a plurality of columns. A perforated skin may be positioned to extend between at least some of the plurality of interconnected buckling walls of at least some of the plurality of columns.

Abstract: A molding system includes a plurality of injection heads each configured to inject molten polymer into a mold cavity. Each injection head has an outer body, a piston disposed within the outer body and defining a polymer chamber on a first side of the piston and a pressure chamber on an opposite second side of the piston. The piston moves from a retracted position to an extended position responsive to pressurization of the pressure chamber. Molten polymer is injected from the polymer chamber into the mold cavity as the piston moves from the retracted position to the extended position. Such systems may be used to mold relatively large articles of manufacture.

Abstract: A cushion includes a cover and a cushioning element having a top surface heat-fused to the cover. The cushioning element comprises an elastomeric material having a plurality of voids formed therein. At least 60% of a bottom surface of the cushioning element is exposed such that when the cushion is disposed over a surface at least 60% of the bottom surface of the cushioning element is in direct contact with the surface. Methods of foaming the cushion include disposing a cover adjacent a mold, conforming the cover to a selected shape of the mold, injecting molten elastomeric material into the mold, bonding the molten elastomeric material to the cover, solidifying the molten elastomeric material to form the cushioning element, and separating the mold from the cover. The cushioning element maintains the cover in the selected shape.

Abstract: Cushioning elements include a breathable material configured to allow gases to pass through at least a portion thereof, and a plurality of discrete segments of thermoplastic elastomeric gel (“gel”) heat-fused or otherwise attached to the breathable material. The gel comprises an elastomeric polymer and a plasticizer, with a plasticizer-to-polymer ratio of from about 0.3 to about 50. The plurality of discrete segments defines at least one breathable gap between adjacent discrete segments. Methods of forming cushioning elements include forming a plurality of discrete segments of gel, securing each segment to a breathable material, and providing a gas path through the breathable material and between adjacent segments. Another method includes providing molten gel within a mold, providing at least a second portion of the gel within a permeable material, and solidifying the gel to form discrete segments of gel.

Abstract: Cushioning elements having a top cushioning surface and a bottom base surface include an elastomeric cushion member and a stabilizing material. The elastomeric cushion member includes a first plurality of interconnected buckling walls having a first mean height and a second plurality of buckling walls having a second mean height. Each buckling wall of the second plurality intersects and connects to at least two buckling walls of the first plurality. A surface of the stabilizing material on a side thereof opposite the elastomeric cushion member defines the bottom base surface of the cushioning element. The first ends of the first plurality of interconnected buckling walls and the first ends of the second plurality of buckling walls define the top cushioning surface of the cushioning element. Methods of forming cushioning elements include securing a stabilizing material to ends of the first plurality of interconnected buckling walls.

Abstract: Cushioning elements include a porous foam comprising a series of interconnected cell walls and an elastomeric material formed over at least a portion of the interconnected cell walls. The porous foam is configured to allow gases to pass through at least a portion thereof. Methods of forming cushioning elements may include coating interconnected cell walls of a breathable porous foam with a liquid comprising an elastomeric material, solidifying at least a portion of the elastomeric material, and providing a gas path through the elastomeric material. Other methods include pressing sheets of foam together at a pinch point, disposing a liquid between the foam over the pinch point, coating the foam with the liquid, and separating the sheets beyond the pinch point. Some methods include consolidating a plurality of portions of porous foam into a continuous cushioning material.

Abstract: A molding system includes a plurality of injection heads each configured to inject molten polymer into a mold cavity. Each injection head has an outer body, a piston disposed within the outer body and defining a polymer chamber on a first side of the piston and a pressure chamber on an opposite second side of the piston. The piston moves from a retracted position to an extended position responsive to pressurization of the pressure chamber. Molten polymer is injected from the polymer chamber into the mold cavity as the piston moves from the retracted position to the extended position. Such systems may be used to mold relatively large articles of manufacture.

Abstract: Cushioning elements having a top cushioning surface and a bottom base surface include an elastomeric cushion member and a stabilizing material. The elastomeric cushion member includes a first plurality of interconnected buckling walls having a first mean height and a second plurality of buckling walls having a second mean height. Each buckling wall of the second plurality intersects and connects to at least two buckling walls of the first plurality. A surface of the stabilizing material on a side thereof opposite the elastomeric cushion member defines the bottom base surface of the cushioning element. The first ends of the first plurality of interconnected buckling walls and the first ends of the second plurality of buckling walls define the top cushioning surface of the cushioning element. Methods of forming cushioning elements include securing a stabilizing material to ends of the first plurality of interconnected buckling walls.

Abstract: Cushioning elements include a porous foam comprising a series of interconnected cell walls and an elastomeric material formed over at least a portion of the interconnected cell walls. The porous foam is configured to allow gases to pass through at least a portion thereof. Methods of forming cushioning elements may include coating interconnected cell walls of a breathable porous foam with a liquid comprising an elastomeric material, solidifying at least a portion of the elastomeric material, and providing a gas path through the elastomeric material. Other methods include pressing sheets of foam together at a pinch point, disposing a liquid between the foam over the pinch point, coating the foam with the liquid, and separating the sheets beyond the pinch point. Some methods include consolidating a plurality of portions of porous foam into a continuous cushioning material.

Abstract: Cushioning elements include a breathable material configured to allow gases to pass through at least a portion thereof, and a plurality of discrete segments of thermoplastic elastomeric gel (“gel”) heat-fused or otherwise attached to the breathable material. The gel comprises an elastomeric polymer and a plasticizer, with a plasticizer-to-polymer ratio of from about 0.3 to about 50. The plurality of discrete segments defines at least one breathable gap between adjacent discrete segments. Methods of forming cushioning elements include forming a plurality of discrete segments of gel, securing each segment to a breathable material, and providing a gas path through the breathable material and between adjacent segments. Another method includes providing molten gel within a mold, providing at least a second portion of the gel within a permeable material, and solidifying the gel to form discrete segments of gel.