Abstract: Mattress assemblies that provide user comfort and increased airflow generally include a viscoelastic thermally conductive infused polyurethane foam top layer; a composite comprising a bottom layer, a molded viscoelastic middle foam layer, and a perforated top viscoelastic foam layer, wherein the molded viscoelastic middle foam layer comprises a plurality of interconnected substantially parallelpipedal bodies, wherein each parallelpipedal body includes an opening extending from a bottom surface to a top surface and is separated from an adjacent parallelpipedal body by a V-shaped notch, and wherein the perforated top viscoelastic foam layer comprises a plurality of perforations extending from a bottom surface to a top surface thereof, wherein at least a portion of the perforations overlies the opening in the parallelpipedal bodies; and a base core layer, wherein the composite overlies the base core layer.

Abstract: Mattress toppers for mattress assemblies generally includes a convoluted foam layer including a convoluted upper surface and a bottom planar surface. The convoluted upper surface includes multiple raised rectangular-shaped foam sections and a plurality of raised spaced apart hemispherical-shaped foam spheres within each of the raised rectangular shaped foam sections; and at least one overlying foam layer including a bottom planar surface in contact with an uppermost surface of the multiple raised rectangular-shaped foam sections.

Abstract: Fibers, fabrics, mattresses and processes of making the fibers generally include a microencapsulated phase change material; and a polymer, wherein the microencapsulated phase change material is greater than 50 percent by weight of the fiber. The process for making the fibers is a dry jet/wet spinning process free of sonication.

Abstract: Mattress toppers for mattress assemblies generally includes a convoluted foam layer including a convoluted upper surface and a bottom planar surface. The convoluted upper surface includes multiple raised rectangular-shaped foam sections and a plurality of raised spaced apart hemispherical-shaped foam spheres within each of the raised rectangular shaped foam sections; and at least one overlying foam layer including a bottom planar surface in contact with an uppermost surface of the multiple raised rectangular-shaped foam sections.

Abstract: Mattress assemblies that provide user comfort and increased airflow generally include a viscoelastic thermally conductive infused polyurethane foam top layer; a composite comprising a bottom layer, a molded viscoelastic middle foam layer, and a perforated top viscoelastic foam layer, wherein the molded viscoelastic middle foam layer comprises a plurality of interconnected substantially parallelpipedal bodies, wherein each parallelpipedal body includes an opening extending from a bottom surface to a top surface and is separated from an adjacent parallelpipedal body by a V-shaped notch, and wherein the perforated top viscoelastic foam layer comprises a plurality of perforations extending from a bottom surface to a top surface thereof, wherein at least a portion of the perforations overlies the opening in the parallelpipedal bodies; and a base core layer, wherein the composite overlies the base core layer.

Abstract: A layer for a bedding product such as a mattress includes an extruded three dimensional polymeric fiber matrix layer having constant length, width and height dimensions, the extruded three dimensional polymeric fiber matrix layer comprising randomly oriented fibers bonded at coupling points between adjacent fibers and having a free volume per unit area of the layer, wherein the fibers comprise a polymer and a phase change material.

Abstract: A three dimensional polymeric fiber matrix layer including a phase change material coated thereon for use in a bedding product such as a mattress is disclosed. The phase change material is selected to provide improved cooling properties, which along with the free volume provided by the three dimensional polymeric fiber matrix markedly improves temperature management when used in a bedding product.

Abstract: A pre-conditioned three dimensionally polymeric fiber matrix layer for use in a bedding product such as a mattress is disclosed. The pre-conditioned three dimensionally polymeric fiber matrix layer generally includes an extruded three dimensional polymeric 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, wherein a portion of the coupling points and the randomly oriented polymer fibers are broken so as to change a mechanical property of the pre-conditioned three dimensionally polymeric fiber matrix layer relative to the three dimensionally polymeric fiber matrix layer without pre-conditioning.

Abstract: A three dimensional polymeric fiber matrix layer for use in a bedding product such as a mattress is disclosed. The three dimensional polymeric fiber matrix layer generally includes a plurality of randomly oriented polylactide (PLA) fibers bonded at coupling points between adjacent PLA fibers and having a free volume per unit area of the layer.

Abstract: The present invention concerns a flame retardant (FR) lofted lightly needlepunch nonwoven fabric useful in household goods and particularly for mattresses. The nonwoven fabric comprises at least one of FR rayon fiber, FR acrylic fiber, FR melamine fiber, FR polyester fiber, FR polyolefin fiber, or FR resin coated fiber and nonbonding, nonFR synthetic and/or natural fiber mechanically bound together by a needlepunch process. The present invention also contemplates a mattress constructed from the FR lofted lightly needlepunch nonwoven fabric comprising FR rayon fiber, FR acrylic fiber, FR melamine fiber, FR polyester fiber, FR polyolefin fiber, or FR resin coated fiber. The mattress from this construction passes the California Test Bulletin 603 stringent conditions for mattresses used in residential places. Preferably the nonwoven fabric has a batt weight of at least 2.25 oz./sq.yd. and preferably between 2.25 oz./sq.yd. and 20 oz./sq.yd.

Abstract: The present invention relates to a process for making high loft, nonwoven material by providing either natural and/or synthetic fibers, providing a low melt binder fiber, mixing the low melt binder fiber and the natural and/or synthetic fibers to form a web, cross-lapping the web, drafting the web with a drafter, heating the drafted web to a temperature sufficient to melt the low melt binder fibers, and cooling the web thereby forming a structural nonwoven material. The nonwoven batt can be cross-lapped between 2 and 10 layers and when the batt is cooled and has structural rigidity, the tensile strength in the machine direction is at least 50% of the tensile strength in the cross-direction. The batt weight is in a range of 0.25 oz/ft2 to 2.0 oz/ft2. The low melt binder fibers comprise 10 to 30 wt. % of the nonwoven batt and the synthetic and/or natural fibers comprise about 70 to 90 wt. %.

Abstract: The present invention relates to process for making a light-weight, high loft nonwoven fabric. The process adds a drafter to a conventional nonwoven process in order to increase the production rate. Additionally, the invented process improves the quality of the manufactured fabric by increasing the tensile strength in the machine direction, providing balanced strength in the machine and cross directions, and enhancing resiliency. The process blends polyester fiber with a low melt fiber or low melt bicomponent fiber to form a web. The web is optionally carded and cross lapped before being drafted. Thereafter, the web is heated in an oven having sufficient heat to melt the low melt fiber then cooled to set the properties.

Abstract: The present invention concerns a mattress having a flammable core and a cellulosic flame-retardant (FR) nonwoven fabric that at least partially encloses the flammable core. The nonwoven fabric comprises from about 65 to about 85 weight percent (wt. %) cellulosic flame retardant fibers, and from about 15 to about 35 weight percent of low melt binder (bicomponent fiber or low-melting fiber), the nonwoven fabric prepared from these components, has a basis weight of about 5 to about 20 oz./sq. yd. and is capable of passing stringent flame-resistant tests. The mattress from this construction passes the California Test Bulletin 129 and/or 603 stringent conditions for mattresses used in public or residential places.

Abstract: The present invention concerns a flame-retardant (FR) nonwoven fabric/article useful in household goods and particularly for mattresses. The nonwoven fabric/article comprises from about 6 to about 40 weight percent of a low melt binder; at least one of FR rayon fiber, FR acrylic fiber, FR melamine fiber, FR polyester fiber, and FR coated fiber; and optionally a synthetic and/or natural fiber. From this nonwoven fabric/article, many household goods such as drapes, curtains, rugs, bedding, and particularly mattresses may be constructed. The present invention also contemplates a mattress constructed from the nonwoven fabric/article comprising FR rayon fibers, FR acrylic fibers, FR melamine fiber, FR polyester fiber, and FR coated fiber, non-FR fibers, and about 6 to about 40 weight percent of a low melt binder. The mattress from this construction passes the California Test Bulletin 129 stringent conditions for mattresses used in public places.